Repair - Parts List LineLazer™ IV 200HS Auto-Layout™ System Airless Line Striper 312226L EN 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 Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. See page 2 for model information.
Models Contents Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tip Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 General Repair information . . . . . . . . . . . . . . . . . . . . . . . . 6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Pressure Relief Procedure . . . . . . . . . . . . . . . . . . .
Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable. WARNING FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode.
Warnings WARNING EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. • Do not operate the unit when fatigued or under the influence of drugs or alcohol. • Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals. • Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings.
Tip Selection Tip Selection in. (cm) * LL5213* 2 (5) LL5215* 2 (5) in. (cm) in. (cm) in.
General Repair Information General Repair Information grounding clamp 1. Keep all screws, nuts, washers, gaskets, and electrical fittings removed during repair procedures. These parts are not normally provided with replacement assemblies. 2. Test repair after problem is corrected. 3. If sprayer does not operate properly, review repair procedure to verify procedure was done correctly. If necessary, see Troubleshooting, page 8, for other possible solutions.
Maintenance Maintenance Pressure Relief Procedure DAILY: Check hose for wear and damage. DAILY: Check gun safety for proper operation. DAILY: Check prime/spray drain valve for proper operation. 1. Engage trigger lock. DAILY: Check and fill the gas tank. 2. Turn engine ON/OFF switch to OFF. DAILY: Check that displacement pump is tight. 3. Move pump valve to OFF and turn pressure control knob fully counterclockwise. 4. Disengage the trigger lock. 5.
Troubleshooting Caster Wheel (See letter call-outs in Parts drawing on page 25.) 3. Once each month, grease the wheel bearing (F). 1. Once each year, tighten nut (127, detail A) until spring washer bottoms out. Then back off the nut 1/2 to 3/4 turn. 4. Check pin (55) for wear. If pin is worn out, there will be play in the caster wheel. Reverse or replace the pin as needed. 2. Once each year, tighten nut (127) until it begins to compress spring washer. Then tighten the nut an additional 1/4 turn. 5.
Troubleshooting Problem Displacement pump operates, but output is low on upstroke Cause Solution Piston ball is not seating. Service piston ball. Manual 309277. Piston packings are worn or damaged. Replace packings. Manual 309277. Displacement pump Strainer (34e) is clogged. operates but output is low O-ring in pump is worn or damaged. on downstroke and/or on Intake valve ball is packed with material or is not both strokes. seating properly. Clean strainer. Replace o-ring. Manual 309277.
Troubleshooting Problem Excessive leakage around hydraulic motor piston rod wiper. Fluid delivery is low. Cause Solution Piston rod seal worn or damaged. Replace these parts. Pressure setting too low. Increase pressure. Manual 312190. Displacement pump outlet filter (if used) is dirty or Clean filter. clogged. Intake line to pump inlet is not tight. The sprayer overheats. Tighten. Hydraulic motor is worn or damaged. Bring sprayer to Graco distributor for repair.
Troubleshooting Problem Cause Spray icon does not show Loose connector. on display when fluid is sprayed. Interrupter (164) is improperly positioned. Reed switch assembly (18) is damaged. Solution Check that 5-pin connector and reed switch are properly connected. Turn screw counterclockwise until spray icon synchronizes with fluid spray. Replace reed switch assembly (18). Magnet on assembly (18) is missing. Replace reed switch assembly (18).
Auto-Layout Can Actuator Adjustment Auto-Layout Can Actuator Adjustment Adjustments The can actuator is set at the factory. If the dot size is not as desired, do the coarse and/or fine adjustments. Coarse Adjustment 1 Locate four screws on side of holder base. ti10072a 4 Carefully tighten screws. Verify gap. ti10070a 2 Loosen screws to allow holder base to move freely.
Auto-Layout System Auto-Layout System Engine Stop Switch 4. Note on paper, lead connections to the control board. Disconnect leads from control board (15d). Removal 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. 1. Relieve pressure, page 7. 2. FIG. 2. Remove two screws (103) and cover (31). 3. Remove two spade connectors from ENGINE STOP switch (15f). 4.
Auto-Layout System 15f 15f 123 B A C D GROUND 15d 31 15k TO ENGINE Main Control Box Cable 103 Transducer 259 124 ti10327a FIG.
Control Board Diagnostics Control Board Diagnostics Display Messages Relieve pressure before repair; page 7. No display does not mean that sprayer is not pressurized. Display Sprayer Operation Indication Action No Display Sprayer may be pressurized. Loss of power or display not connected. Sprayer may be pressurized. Pressure less than 200 Increase pressure as needed. psi (14 bar, 1.4 MPa). Check power source. Relieve pressure before repair or disassembly. Verify display is connected.
Trigger Sensor Adjustment Trigger Sensor Adjustment Refer to Troubleshooting for trigger sensor adjustment, and 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. 273 115 66 120 272 130 127 142 TI10237a FIG.
Hydraulic Pump Hydraulic Pump Removal 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). 1. Allow hydraulic system to cool before beginning service. 2. Relieve pressure, page 7. 3. Place drip pan or rags under sprayer to catch hydraulic oil that leaks out during repair. 4. Fig. 4. Remove drain plug (195) and oil filter (199) and allow hydraulic oil to drain. 2.
Hydraulic Pump 260 12 143 182 102 251 63 86 169 196 252 162 178 24 32 180 35 218 199 224 184 237 215 A 85 241 195 TI6551a FIG.
Fan Belt Fan Belt Removal 5. Remove belt from fan pulley (86) and fan pulley (87a). Installation 1. Relieve pressure, page 7. 1. Thread belt (143) around fan pulley (87a) and fan pulley (86). 2. FIG. 5. Loosen belt guard knob (241). 2. Lower engine (185) to put tension on belt. 3. Rotate belt guard (24) up. 3. Rotate belt guard (24) down. 4. Lift engine (185) up to remove tension on belt (143). 4. Tighten belt guard knob (241). 24 143 185 86 87a 241 TI6511a FIG.
Engine Engine Removal 7. Remove four screws (189), washers (114), washers (170) and nuts (118) and remove rocker plate, dampeners (59) and washers (114) from engine. All service to the engine must be performed by an authorized HONDA dealer. 1. Relieve pressure, page 7. Installation 2. Remove throttle cable from engine. 3. Do Fan Belt, Removal; page 19. 4. Loosen hand nut (241). Swing bracket (30) out. 5. FIG. 6. Disconnect red, yellow and white/red leads from engine. 6.
Hydraulic Motor Rebuild Hydraulic Motor Rebuild Installation Removal FLYING PARTS HAZARD 1. Slide piston rod assembly (A) into hydraulic motor cylinder (69). 1. Relieve pressure, page 7. 2. Place drip pan or rags under sprayer to catch hydraulic oil that leaks out during repair. 3. Remove pump, page 24. 4. FIG. 7. Remove hydraulic lines (35, 250) from fittings (217) at top left and right side of hydraulic motor. 5. Loosen jam nut (183). 6. Unscrew and remove hydraulic motor cap (25). 7.
Hydraulic Motor Rebuild 217 25 Test Hole A 217 35 250 ti8817a 183 69 TI8818a FIG.
Oil/Filter Change Oil/Filter Change Removal 3. Check oil level. 1. Place drip pan or rags under sprayer to catch hydraulic oil that drains out. 2. FIG. 4. Remove drain plug (195). Allow hydraulic oil to drain. 199 3. FIG. 8. Unscrew filter (199) slowly - oil runs into groove and drains out rear. Installation 1. Install drain plug (195). Apply a light coat of oil to oil filter gasket and install oil filter (199). Tighten oil filter 3/4 turn after gasket contacts base. 2. Fill with 1.25 gallons (4.
Displacement Pump Displacement Pump See manual 309277 for pump repair instructions. Removal 1. Flush pump. TI6516a 2. 3. Relieve pressure, page 7. FIG. 11. Remove suction tube (34) and hose (26). FIG. 13 Installation CAUTION If the pump jam nut loosens during operation, the threads of the hydraulic motor manifold will be damaged. Tighten jam nut as specified. 26 1. 34 TI6514a FIG. 14. Screw jam nut to bottom of pump threads. Screw pump completely into manifold.
Parts Parts LineLazer IV 200HS Parts Page 30 Parts Page 32 Parts Page 34 Parts Page 28 Parts Page 36 Parts Page 26 Parts Page 29 Sheet 1 of 7 312226L ti10325a 25
Parts 268 57 144 141 267 27 264 177 129 107 5 33 60 108 35 73 177 108 93 154 77 84 261 42 112 74 58 261 134 117 28 177 70 273 115 94 13 121 257 66 272 258 68 277 16 108 117 130 122 127 142 51 99 300 117 256 TI14596A 120 To remove cover (257), press tabs together and pull cover away from plate (99).
Parts LineLazer IV 200HS Ref Part Description 5 13 16 27 28 33 35 42 51 57 58 60 66 68 70 73 74 77 84▲ 93 94 99 107 108 109 237686 245225 287623 287417 287622 287590 119771 108471 193405 194310 195134 196176 15K357 15J088 198891 198930 198931 114271 15F638 15F577 15F576 15F425 178342 101566 102478 CLAMP, grounding assy HOSE, 3/8 in.
Parts LineLazer IV 200HS 49 108 95 136 153 136a 83 112 104 1 44 8f 8e 161 8b 105 8f 8d 1 8f 47 8 14 8a 8c Detail 8 8f ti6494a 4 71 160 72 119 Ref 144 Ref 27 161 119 2 162 89 96 18 126 163 71 Ref 161 17 164 165 1 Torque to 90-110 in-lb. 2 Torque to 10-20 in-lb.
Parts LineLazer IV 200HS Ref Part 1 4 8 8a 8b 8c 8d 8e 8f 14 17 224052 248157 287570 287569 15F214 15F209 15F210 15F211 102040 245798 245733 18 44 46 47 49 71 72 83▲ 89▲ 287699 15F212 111145 15F213 188135 198895 198896 15F637 15A644 Description Qty BRACKET, support gun GUN, flex, basic, includes guard & tip KIT, holder, gun HOLDER, gun LEVER, actuator STUD, pull, trigger STUD, pivot STUD, cable NUT, lock HOSE, 1/4 x 7 ft KIT, trigger handle repair, includes 89, 126, 164, 165 KIT, sensor ARM, suppor
Parts LineLazer IV 200HS 103 15u 15d 225 123 15k 191 15c 190 15b 125 15m 15s 15f 268 12 330 15a 15r 15w 109 269 15x 15t 15n 31 Ref 27 331 332 41 167 103 37 11 29 262 271 62 76 259 2a 13 97 124 38 2c 2d 2 2b 64 62 Ref 34 Ref 26 30 Sheet 4 of 7 ti17487a 312226L
Parts LineLazer IV 200HS Ref 2* 2a 2b 2c 2d 11* 12 13 15 Part 245103 193709 193710 116424 114708 244067 287687 245225 289264 15a 15b 15c 15d 15f 15k 15m 15n 15r 15s 15t 15u 15w 15x 29 31 37* 38* 15G801 289265 15M509 289135 114954 111839 120743 109466 287692 119736 15F777 15F776 196179 15F589 15C766 15G563 312226L Description Qty VALVE, drain 1 SEAT, valve 1 SEAT, valve 1 NUT, cap 1 SPRING 1 FILTER, fluid 1 KIT, repair, pressure control 1 HOSE, 3/8 in.
Parts LineLazer IV 200HS 231 138 217 159 243 7 25 217 2 250 35 149 284 6 173 235 2 48 213 213 187 158 183 69 186 220 166 3 107 32 174 108 230 244 137 179 245 233 283 92 222 35 218 194 26 60 3 21 2 Torque to 130-150 in-lb.
Parts LineLazer IV 200HS Ref 21 Part Description 277068 PUMP, displacement Manual 309277 25◆ 288754 KIT, trip rod, piston, cap 26 245797 HOSE, coupled, 3/8 in.
Parts LineLazer IV 200HS 260 227 185 12 102 43 182 63 86 196 88 169 252 143 251 178 125 Ref 32 24 118 150 87b 180 114 59 188 87a 181 82 172 184 212 253 162 214 87c 199 228 193 170 81 114 197 189 237 224 215 23 75 174 198 255 254 34k 34f 85 241 34d 241 34h 30 34n 34g 34b 34j 34a 117 242 170 195 34e 200 34d Detail 34 34c Sheet 6 of 7 34 TI6493b 312226L
Parts LineLazer IV 200HS Ref 12 23 24 Part 287687 288261 288734 30 34a 34b 34c 34d 34e 34f 34g 34h 34j 34k 34m 34n 43 59 63 75 81 82 85 86 87a 87b 87c 88 102 114 117 118 125 143 150 151 162 15E476 170957 194306 198119 101818 181072 245731 241920 248008 114958 196180 195119 15F513 15C400 15E888 15C958 15E587 240997 15K638 120604 16U205 15E758 15E759 15F485 117632 112303 108851 110837 110838 101962 119433 154594 114956 116969 312226L Description SHAFT, flexible, includes 102, RAIL, belt GUARD, belt, inc
Parts LineLazer IV 200HS Ref 141 56 146 142 127 130 1 117 133 121 10 113 46 54 128 133 153 7 132 116 147 55 108 139 106 52 127 139 110 209 130 1 Detail A 53 65 46 6 140 F 135 145 Detail A 131 1 36 Install washers (130) concave surface to inside.
Parts LineLazer IV 200HS Swivel Wheel Assembly 240719 Ref 6 7 10* 46 52 53 54 55 56 65 106 108 110 113 116 117 121 Part 240942 240991 15G952 181818 193528 193658 193661 193662 15F910 198606 100731 101566 15J603 108483 110754 110837 111040 312226L Description SHAFT, fork BRACKET, caster, front BRACKET, hub KNOB, pronged ARM, detent SPACER, seal JAW STOP, wedge BRACKET, cable DISK, adjuster WASHER NUT, lock WASHER, plain SCREW, shoulder, soc hd SCREW, cap, soc hd SCREW, flange, hex NUT, lock Qty 1 1 1 1
Auto-Layout System Wiring Diagram Auto-Layout System Wiring Diagram Red clip on yellow YELLOW WHITE/YELLOW A4 5900 A3 TO ENGINE WHITE/RED 81, page 35 GROUND RED A2 ENGINE OFF SWITCH TRANSDUCER A1 A6 DISPLAY BOARD SOLENOID CONNECTOR GUN TRIGGER REMOTE BUTTON DISTANCE SENSOR A5 J15 J9 J8 J10 JUNCTION BOX J16 J17 J5 CONTROL BOARD J11 A8 J12 PUMP STROKE COUNTER PUMP ON/OFF SWITCH J4 J3 J1 J2 TO ENGINE GENERATOR A7 A6 A8 PUMP STOKE COUNTER A7 J12 WHITE WHITE K /BLAC A4 A3 A1 A
Technical Data Technical Data Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Generator Output . . . . . . . . . . . . . . . . . . . . . . . . . Maximum working pressure . . . . . . . . . . . . . . . . . . . . . . . Noise Level Sound power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sound pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *Vibration Level Left hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.
