LINEAR DYNAMICS 160 Airless HD Owner's Manual

5.5 hp gasoline-powered airless linestriper

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LINEAR DYNAMICS INC.

5.5 HP GASOLINE-POWERED AIRLESS LINESTRIPER

Model 160 Airless HD

3000 psi (210 bar, 21.0 MPa)

Maximum Working Pressure

Model 231–150, Series C

With one gun, RAC IV DripLess

Size 317 LineLazer Tip & Size 517 SwitchTip ,

and 50 foot (15 m) hose.

Model 231–152

Same as 231–133, except includes

Second Gun Kit, 224–097

LINEAR DYNAMICS INC., 400 LANIDEX PLAZA. PARSIPPANY, NJ 07054

This manual contains important

warnings and information.

READ AND RETAIN FOR REFERENCE

Tip guard,

(201) 884–0300

Graco Inc. is registered to I.S. EN ISO 9001

OWNER'S MANUAL

308–134

Rev. P

Supersedes M

02154D

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Summary of Contents for LINEAR DYNAMICS 160 Airless HD

Page 1 50 foot (15 m) hose. Model 231–152 Same as 231–133, except includes Second Gun Kit, 224–097 02154D LINEAR DYNAMICS INC., 400 LANIDEX PLAZA. PARSIPPANY, NJ 07054 (201) 884–0300 COPYRIGHT GRACO INC, 1991 Graco Inc. is registered to I.S. EN ISO 9001...
Page 2 Part Identification Caster lever Dual gun selector Main hose Suction hose Fluid filter Pressure drain valve G Arm Post Carriage bar Gun holder Rac IV tip guard M Switch Tip Flex gun O Displacement pump Caster Q Dual gun selector cable Pressure control Spark plug cable Air Cleaner...
Page 3: Table Of Contents
Table of Contents Warnings ........Caster Alignment .
Page 4: Warnings
Symbols Warning Symbol Caution Symbol WARNING CAUTION This symbol alerts you to the possibility of serious This symbol alerts you to the possibility of damage to injury or death if you do not follow the instructions. equipment if you do not follow the instructions. WARNING EQUIPMENT MISUSE HAZARD Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
Page 5 WARNING INJECTION HAZARD Spray from the gun, leaks or ruptured components can inject fluid into your body and cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also cause serious injury. Fluid injected into the skin may look like just a cut, but it is a serious injury.
Page 6 WARNING FIRE AND EXPLOSION HAZARD Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result in a fire or explosion and serious injury. If there is any static sparking or you feel an electric shock while using this equipment, stop spray- ing immediately.
Page 7: Setup
Setup General Information Pressure Relief Procedure NOTE: Reference numbers and letters in parentheses WARNING in the text refer to the callouts in the figures and the parts drawing. INJECTION HAZARD Fluid under high pressure can be in- NOTE: Always use Genuine Graco Parts and Acces- jected through the skin and cause seri- sories, available from your Graco distributor.
Page 8 Setup 1. Read and follow the warnings on pages 4–6 be- 7. Provide adequate ventilation when spraying indoors. fore installing or operating this sprayer. 2. Unpack the Linestriper Carefully raise the handle WARNING (19) to a vertical position. Four screws (39) and lock- nuts (40) are packed in a bag.
Page 9 Setup 11. Observe the following cautions to avoid pressure 12. To use the wheel brake, lift the brake handle (A– control damage. bottom rear of cart) to engage the brake. Lower the handle to disengage the break. See Fig. 5. For positive break engagement, be sure there is CAUTION proper tire pressure and that tire wear is not...
Page 10: Fueling
Fueling NOTE: The HONDA engine warranty does not cover WARNING damage resulting from the use of gasolines containing al- cohol. See the HONDA engine manual for more informa- Gasoline is extremely flammable and explosive tion. under certain conditions. To reduce the risk or a fire 3.
Page 11: Second Gun And Hose Installation
Second Gun and Hose Installation NOTE: Fig. 7 represents the installation at Step 3. 6. Disconnect the trigger cable from the second gun at the screw (34). See Fig. 7 DETAIL B. NOTE: To switch the gun assemblies to the engine side of the cart, refer to the instructions on page 17 before in- 7.
Page 12: Flushing
Flushing WARNING WARNING To reduce the risk of serious injury whenever you To reduce the risk of static sparking and splashing are instructed to relieve pressure, always follow the when flushing, always remove the spray tip from Pressure Relief Procedure on page 7. the gun, and hold a metal part of the gun firmly to the side of, and aimed into, a grounded metal pail.
Page 13: Startup
Startup Before You Start the Linestriper g. Open the choke as soon as the engine starts, except in cold weather. In cold weather, leave 1. See Flushing, page 12, to determine if the Linestriper the choke closed for 10 to 30 seconds before should be flushed.
Page 14 Startup 15. Read Spray Techniques on page 16. CAUTION Close the black fuel shutoff lever (E) whenever you are transporting the sprayer to prevent fuel from flooding the engine. Keep the sprayer upright and level when operating it and when transporting it. This prevents crankcase oil ––AT REAR OF ENGINE––...
Page 15: Spray Tip And Tip Guard
Spray Tip and Tip Guard Operation WARNING WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Keep clear of the nozzle! High pressure fluid from Pressure Relief Procedure on page 7. leaks or spray can penetrate the skin and cause extremely serious injury, including the need for amputation.
Page 16: Spray Tip Selection
Spray Tip Selection Spray Tip Application Recommendations Other Applications Sport Court, Lineal Feet/Minute 2” wide line LLT–213* (rate at which unit is moved) Crosswalk, Based on 4” wide line and 15 mils of paint 12” wide line, 1 gun 621, 623, 625 Application Airport,...
Page 17: Positioning The Gun Arm Assembly
Positioning the Gun Arm Assembly PUMP SIDE ENGINE SIDE 405B 0012E DETAIL A 405A 0059 “WINGS” OF TIP GUARD Fig. 15 The gun arms can be positioned for a variety of spraying Horizontal Position of the First Gun needs. The drawings on page 19 primarily show the guns Method 1: Disengage the trigger cable.
Page 18: Mount Guns On The Engine Side Of The Cart
Positioning the Gun Arm Assembly Mount Guns on the Engine Side of the Cart 7. Install the guns. Note which gun and position on the dual gun selector each of the cables (1 and 402) 1. For both guns, disengage the trigger cable and en- goes.
Page 19: Gun Arm Positions
Gun Arm Positions SINGLE LINE ONE GUN CURB DOUBLE LINE OR SINGLE LINE UP TO 24” WIDE TWO GUN CURB 0017A DOUBLE LINE OR SINGLE LINE UP TO 24” SINGLE OR DOUBLE LINE; SPRAYING AROUND OBSTACLES WIDE...
Page 20: Caster Lever & Cable Operation
Caster Lever and Cable Operation Maintenance See Fig. 18 CAUTION Paint builds up on the caster triggering mechanism. To keep it operating properly, use a grease gun at the grease The AccuTrack caster is factory-adjusted to track zerks (32A, 32B) to flush out the buildup – two to four in a straight line.
Page 21: How The Dual Gun Selector Works
Trigger Cable & Dual Gun Selector Operation How to Release the Dual Gun Selector Shown in Cable three positions WARNING The gun is remotely triggered with a dual gun selector on the handle bar. 112d To reduce the risk of an injection injury due to 1 or 402 remotely triggering the gun by accident, always 0021...
Page 22 Trigger Cable & Dual Gun Selector Operation Trigger Cable Tension Adjustment 1 or 402 See Fig. 21 FORWARD 1. Relieve pressure. See page 7. 2. Be sure the gun is properly mounted in the holder as instructed on page 20. 3.
Page 23: Maintenance
Maintenance After the first 20 hours of operation and each 100 WARNING hours thereafter: Change the oil. Weekly: Remove the air filter cover and clean the ele- To reduce the risk of serious injury always follow ment. In very dusty environments, check the filter daily. the Pressure Relief Procedure on page 7, Replace the element as needed.
Page 24: Troubleshooting
Troubleshooting WARNING To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the Pressure Relief Procedure on page 7. Check everything in the chart before disassembling the sprayer. PROBLEM CAUSE SOLUTION Engine/sprayer won’t start Engine switch not on Turn on engine switch.
Page 25 Troubleshooting PROBLEM CAUSE SOLUTION Displacement pump output low on Pump inlet screen clogged Clean screen. downstroke or both strokes Pressure setting too low Increase pressure. See Startup, Step 14, page 13. Dirty outlet filter, tip filter or tip Clean filters and/or tips. Piston packings worn or damaged Replace packings.
Page 26: Pressure Control
Pressure Control WARNING WARNING To reduce the risk of serious injury whenever you To reduce the risk of electric shock, be sure all are instructed to relieve pressure, always follow the grounding features of the pressure control are Pressure Relief Procedure on page 7. properly assembled: Ground wire (308) connected in pressure con- 1.
Page 27: Pressure Control Adjustment
Pressure Control Adjustment WARNING Use extreme caution when performing this calibra- plosion. It may also prevent the sprayer from obtaining tion procedure to reduce the risk of a fluid injection in- the maximum working pressure, resulting in poor jury or other serious bodily injury, which can result from sprayer performance.
Page 28: Bearing Housing And Connecting Rod
Bearing Housing and Connecting Rod 9. Install the screws (81) and lockwashers (46) on the WARNING bearing housing. Tighten the screws evenly to 175 in–lb (20 N.m). To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the 10.
Page 29: Drive Housing
Drive Housing WARNING CAUTION Do not drop the gear cluster (78) when removing the To reduce the risk of serious injury whenever you drive housing (77). The gear cluster is easily dam- are instructed to relieve pressure, always follow the aged.
Page 30: Pinion Housing
Pinion, Clutch, Clamp, Field, & Engine Disassembling these parts can start from the pinion If starting from the pinion housing , first follow Steps housing or from the clutch, if no pinion service is 1 to 6 of DRIVE HOUSING, on page 29, and then contin- needed.
Page 31 Pinion Housing DETAIL A Back of pinion housing 0041 Press fit small bearing (138c) and roller clutch (138g) in here 138p Lubricate exterior Lubricate inner and outer diameters Lubricate teeth 138m 138a 138n 138e CUTAWAY VIEW OF PINION 138f HOUSING (138p) 138d 138b 138g...
Page 32: Clutch
Clutch NOTE: The clutch assembly (55) includes the armature 4. Tap lightly on the back of the drive housing (77) with (55a) and rotor (55b). The armature and rotor must be re- a plastic mallet to loosen the assembly (D) from the placed together so they wear evenly.
Page 33 Clutch Rotor/Field Adjustment Adjustment See Fig. 34 WARNING 1. Remove any residue from the clutch housing (61). To reduce the risk of serious injury whenever you 2. Seat the field (70) squarely in the clutch housing. are instructed to relieve pressure, always follow the Do not tighten the four field set screws (62).
Page 34: Engine
Engine 1. Working under the mounting plate (25) of the cart, re- 3. Lift the engine carefully and place it on a work bench. move the screw (51), lockwasher (132) and washer (50) which hold the clutch housing (61) to the cart. 4.
Page 35: Field & Wiring Harness
Field & Wiring Harness NOTE: Refer to Fig. 37. 2. Pull the caps (A) off the wire screws (57) in both places on the field. Loosen the screws and release 1. Loosen the four setscrews (62) holding the field (70) the wires (58).
Page 36: Clamp
Clamp NOTE: A standard steering wheel puller is re- quired to remove the clamp. Two 1/4–28 x 3 or 4 in. long screws are also needed. NOTE: Refer to Fig. 38. 1. Loosen the two screws (60) on the clamp (68), working through the slot at the bottom of the clutch housing (61).
Page 37: Reassembly
Reassembly 1. Install the clutch housing (61), capscrews (156) Face of housing and lockwashers (157) on the engine. See Fig. 40. 1.99” (50.55 mm) 2. Install the engine shaft key (66). See Fig. 40. Torque to 125 in–lb (14 N.m) 3.
Page 38 Reassembly 5. Place the engine (64) assembly on the cart. Align After installing the rotor (55b), pull the engine recoil the mounting holes. Guide the engine wire (A) rope to assure that the engine turns freely, and there through the clamp at the the rear of the mounting is no friction between the between the rotor (55b) and plate (25).
Page 39: Pressure Control Parts
Parts –Pressure Control Part No. 222–369 – Replacement Pressure Control for All GM 5000 Sprayers Part No. 222–369 includes all items marked with a . It does not include unmarked items. Order the Basic Control, 222–369, and/or items 309 or 313 as needed. Ref.
Page 40 Parts – Cart Ref 13 REF 3 See page 41 Label 114d See page 44 02167A See page 42 114a 114c 114b 114e...
Page 41 Parts – Cart Model 231–150, Series C With one gun Model 231–152 With two guns Includes items 1–190 Includes items 1–190, and 401–405 (see pages 43 and 44) (see pages 43 and 44) Ref. Ref. Part No. Description Qty. Part No. Description Qty.
Page 42 Parts – Mechanical REF 24 REF 25 REF 86 REF 133 Ref 2 REF 133 Label See page 40 See 307–806 Located on bottom Located on inside of cover Ref 84 Located on outside of cover 02168B...
Page 43 Parts – Mechanical Ref. Ref. Part No. Description Qty. Part No. Description Qty. 162–453 NIPPLE, hex 1/4 npt x 1/4 npsm 183–169 SPRING, retaining 1-3/16” long 220–639 BEARING HOUSING KIT 238–960 VALVE, pressure relief 220–638 DRIVE HOUSING 220–285 CAP, secondary fluid outlet Includes items 77a to 77c 162–453 NIPPLE, hex, 1/4 npt x 1/4 npsm...
Page 44 Parts – Gun Mounting Ref. Part No. Description Qty. 224–052 BRACKET, gun support 1 114–029 CLAMP, arm support 114–028 . NUT, wing 188–135 GUIDE, cable 100–846 FITTING, lubrication 111–016 BEARING, flanged REF 1 111–230 SCREW, mach, flhd, 1/4–20 x 1” 100–015 NUT, hex, 1/4–20 100–016...
Page 45 Parts – Pinion Assembly Ref No. 138 Ref. Part No. Description Qty. Pinion Housing Includes items 138a to 138f NOTE: Items 138h to 138p are not included in a kit. Or- Ref. der them separately as needed. Part No. Description Qty.
Page 46: Technical Data
Technical Data Engine ................5.5 Horsepower, Honda Maximum Working Pressure .
Page 47 Notes...
Page 48: Warranty
The LDI Warranty and Disclaimers WARRANTY Linear Dynamics Inc. (LDI) warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized LDI distributor to the original purchaser for use.

This manual is also suitable for:

231-150 231-152