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Graco LineLazer IV 3900, Repair Parts List Manual

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Graco LineLazer IV 3900 Repair Parts List Manual Download Page 13

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.

F

IG

. 12. Remove junction box (226).

3.

F

IG

. 11. Disconnect pump stroke sensor and clutch 

cables.

4.

F

IG

. 4.  Remove four screws (189) and lockwashers 

(188) and pinion assembly (25).

5.

F

IG

. 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.

F

IG

. 6. Remove retaining ring (25e).

8.

Tap pinion shaft (25d) out with plastic mallet.

Clutch Armature

9.

F

IG

. 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).

F

IG

. 4

189

188

189

188

25

TI5480b

85

F

IG

. 5

F

IG

. 6

F

IG

. 7

E

TI5481b

TI5987c

E

172

175

25d

25e

25c

86

TI5482b

87

172

175

TI8704a

Summary of Contents for LineLazer IV 3900

Page 1: ...m 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 ...

Page 2: ...d 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 Turkish 312202 Greek 312203 Croatian 312204 Portuguese 312205 Danish 312206 Fi...

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: ...s 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 th...

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: ...l 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 ...

Page 7: ...rn 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 Electrica...

Page 8: ...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 Re...

Page 9: ...ay 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 Re...

Page 10: ...fully 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 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 dot size of approximately a dime is achieved Tighten ...

Page 11: ...ronze 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...

Page 12: ...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 1...

Page 13: ...n 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...

Page 14: ... 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 ...

Page 15: ...e 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 ...

Page 16: ...ine 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 ...

Page 17: ...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 sc...

Page 18: ... 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 contr...

Page 19: ...stallation 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 dista...

Page 20: ...ressure 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 c...

Page 21: ...IG 19 Screw jam nut onto pump until nut stops Screw pump into bearing housing until stopped by jam nut Back off pump and jam nut to align pump outlet to back Hand tighten jam nut then tap 1 8 1 4 turn with a 20 oz hammer to approximately 75 5 ft lb 102 N m 4 FIG 20 Fill packing nut with Graco TSL until fluid flows onto the top of seal FIG 15 FIG 16 FIG 17 100 A 34 TI7672c TI7675b 235 TI7673b If pi...

Page 22: ...Parts 22 312195B Parts LineLazer IV Sheet 1 of 7 Page 24 Page 31 Page 28 Page 26 Page 30 Page 32 ti10062a ...

Page 23: ...zer IV 5900 1 24h WASHER 116191 LineLazer IV 3900 1 116192 LineLazer IV 5900 1 Ref Part Description Qty 25 287463 HOUSING pinion 3900 1 287465 HOUSING pinion 5900 1 25a KIT repair coil 287474 LineLazer IV 3900 1 287476 LineLazer IV 5900 1 25b 105489 PIN 2 25c O RING 165295 LineLazer IV 3900 1 114683 LineLazer IV 5900 1 25d PINION SHAFT 241110 LineLazer IV 3900 1 241114 LineLazer IV 5900 1 25e RETA...

Page 24: ...154 93 177 177 94 220 153 28 73 117 70 58 74 134 16 51 122 153 177 232 117 115 121 117 115 121 108 177 112 107 35 108 127 142 13 60 14 141 27 5 129 33 154 93 177 94 220 153 28 73 117 70 58 74 134 16 51 122 108 153 177 117 115 121 117 115 121 108 177 107 35 TI7495b Sheet 3 of 7 267 268 277 273 115 68 272 66 120 57 77 130 ...

Page 25: ...108 101566 NUT lock 16 109 102478 STRAP wiring tie not shown 4 112 111145 KNOB pronged 2 115 108868 CLAMP wire 3 117 110837 SCREW flange hex 10 120 255162 WHEEL pneumatic 2 121 111040 NUT lock insert nylock 5 16 6 122 111194 SCREW cap flang hd 2 127 112405 NUT lock 4 129 112798 SCREW thread forming hex hd 1 130 119563 WASHER spring 4 134 113961 SCREW cap hex hd 1 141 241445 CABLE swivel wheel 1 14...

Page 26: ...4k 34j 34d 34c 34f 34e 83 233 187 188 183 258 117 100 60 34 Detail E 21 84 22 259 235 236 26 158 182 190 189 23 181 178 179 212 189 170 172 86 247 Ref 25 page 23 175 172 81 175 172 186 188 85 189 88 185 234 117 108 114 59 174 96 248 249 260 223 118 226 177 Detail E 12 TI6405c Ref 24 page 23 Models 253920 253921 87 82 Ref 16 page 24 261 ...

Page 27: ... lock 16 114 108851 WASHER plain 4 117 110837 SCREW flange hex 10 118 110838 NUT lock 2 158 114528 SCREW mach phillips pnhd 2 170 101682 SCREW cap sch 4 172 105510 WASHER lock spring hi collar 10 174 113743 SCREW cap hex hd 4 175 108803 SCREW hex socket head 6 177 112395 SCREW cap flng hd 5 178 114672 WASHER thrust 1 179 114699 WASHER thrust 2 181 116618 MAGNET 1 182 119562 SWITCH reed w connector...

Page 28: ...19 TI6404b Sheet 5 of 7 1 Install washers 130 concave surface to inside 1 208 Ref 6 F 140 131 56 117 7 153 Ref 141 147 127 130 106 108 Detail D Ref 141 page 24 Ref 16 page 24 142 130 10 46 55 139 65 6 135 145 209 110 52 116 132 133 128 54 113 133 127 Models 253920 and 253921 Detail D 121 1 146 ...

Page 29: ...13 108483 SCREW shoulder sch 1 116 110754 SCREW cap 2 117 110837 SCREW flange hex 10 121 111040 NUT lock insert nylock 5 16 6 127 112405 NUT lock 4 128 112776 WASHER 1 130 119563 SPRING belleville 2 131 113471 SCREW cap hex hd 1 132 113484 SEAL 1 133 113485 BEARING 2 135 113962 WASHER 1 139 114548 BEARING bronze 2 140 114549 WHEEL pneumatic 1 141 241445 CABLE 1 142 114648 CAP dust 3 145 114681 SCR...

Page 30: ...t System 1 2 1 2 TI6497a 160 119 72 71 227 Ref 161 166 164 163 165 71 17 126 89 162 119 Ref 144 page 24 4 Ref 14 161 8b 8a 47 8e 8d 8c 8b 8f 104 112 105 153 219 95 44 1 136a 49 136 Models 253920 and 253921 Sheet 6 of 7 108 ti6494a 8 Torque to 90 110 in lb Torque to 10 20 in lb ...

Page 31: ...ulder socket head 1 161 287696 CABLE gun includes 227 1 162 116969 NUT lock 1 163 116973 SCREW 10 taptite phil 1 164 117268 BRACKET interrupter 1 165 117269 SPRING 1 166 287699 SENSOR trigger 1 219 15F637 LABEL GMax warning skin inject 1 227 15F624 NUT cable gun knurled 2 Included in Trigger Repair Kit 245733 Replacement warning labels may be ordered free of charge Ref Part Description Qty ti10236...

Page 32: ...V Auto Layout System TI6399c 15g 15p 15r 15v 15f 15q 15a 15d 15j 15w 15s 15z 15h 15n 15b part of 15h 15o 125 41 167 37 63 62 Ref 13 76 2 3 39 38 Ref 14 Ref 100 64 62 40 217 216 97 92 Ref 27 215 125 31 123 Models 253920 and 253921 11 15k 15m 15c 15u 125 Sheet 7 0f 7 ...

Page 33: ...ABEL control bottom 1 15s 287692 KIT control throttle 1 15u 119736 CLAMP 1 15v 15F777 GASKET control 1 15w 15F776 GASKET throttle 1 15z 109466 NUT lock hex 2 31 15F589 COVER control 1 37 15C766 TUBE diffusion 1 38 15C780 HANDLE 1 39 15C972 PIN grooved 1 40 15H561 MANIFOLD 1 41 287285 KIT repair filter cap includes 37 167 1 62 196178 ADAPTER nipple 3 63 196179 FITTING elbow street 1 64 196181 FITTI...

Page 34: ...out System Wiring Diagram 34 312195B Auto Layout System Wiring Diagram FIG 21 GREY GREY ref 268 119579 240997 WHITE BLACK VIOLET VIOLET WHITE GREEN WHITE GREEN 1 BLUE 2 BLACK 3 WHITE BLUE 4 BLACK WHITE ti10235a ...

Page 35: ...ft hand Right hand Vibration measured per ISO 5349 based on 8 hour daily exposure 1 81 m sec2 1 45 m sec2 2 05 m sec2 1 70 m sec2 Maximum delivery LineLazer IV 3900 LineLazer IV 5900 1 15 gpm 4 4 liter min 1 5 gpm 5 7 liter min Maximum tip size LineLazer IV 3900 LineLazer IV 5900 1 gun with 0 034 in tip 2 guns with 0 024 in tip 1 gun with 0 041 in tip 2 guns with 0 028 in tip Inlet paint strainer ...

Page 36: ...m Model 253953 255152 Striper with 2nd Gun Kit Weight dry without packaging 222 lb 101 kg Height 40 in 101 6 cm Length 65 in 165 1 cm Width 32 in 81 3 cm Model 253921 255153 Striper Weight dry without packaging 232 lb 105 kg Height 40 in 101 6 cm Length 65 in 165 1 cm Width 32 in 81 3 cm Model 253954 255154 Striper with 2nd Gun Kit Weight dry without packaging 242 lb 110 kg Height 40 in 101 6 cm L...

Page 37: ...Dimensions 312195B 37 ...

Page 38: ...incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by G...

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