Graco 3A3394E, LineLazer V 250SPS and 250DC, Line Striper, Repair/Parts Owner's Manual

Repair - Parts
LineLazer V 250SPS and 250DC
Self-Propelled Line Striper
For the application of line striping materials.
For professional use only. For outdoor use only.
Not for use in explosive atmospheres or hazardous locations.
Maximum Operating Speed: 10 mph (16 kph)
Maximum Operating Pressure: 3300 psi (22.8 MPa, 228 bar)
IMPORTANT SAFETY INSTRUCTIONS
Read all warnings and instructions in this manual and in related manuals.
Be familiar with the controls and the proper usage of the equipment.
Save these instructions.
Model
Guns
Pressurized
Bead System
Description
17H471
2
No
LLV 250DC
17H472
3
No
LLV 250DC
17H473
2
Yes - 2 Tank
LLV 250DC
25P365
2
Yes - 2 Tank
LLV 250DC
17H474
3
Yes - 2 Tank
LLV 250DC
17H466
1
No
LLV 250SPS
17H467
2
No
LLV 250SPS
17H468
1
Yes - 1 Tank
LLV 250SPS
17J951
2
Yes - 1 Tank
LLV 250SPS
17H469
2
Yes - 2 Tank
LLV 250SPS
Related Manuals:
3A3393
311254
309277
3A3428
332230
3A6981
Operation
Gun
Pump
Auto-Layout Applications Methods
Pressurized Bead System (PBS)
Steering Cable Replacement
ti23089a
Use only genuine Graco replacement parts.
The use of non-Graco replacement parts may void warranty.
3A3394E
EN
Table of Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component Identification (LLV 250DC Shown) . . 8
Component Identification (Controls) . . . . . . . . . . . 9
Grounding Procedure
(For Flammable Materials Only) . . . . . . . . . . 10
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 10
Ground Drive Belt Replacement . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Oil Reservoir Belt Replacement . . . . . . . . . . . . . . 12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hydraulic System Purging . . . . . . . . . . . . . . . . . . 13
Ground Drive Pump Replacement . . . . . . . . . . . . 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Oil Reservoir Pump Replacement . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Hydraulic Gun Manifold Replacement . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Paint Pump Replacement . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hydraulic Motor Replacement . . . . . . . . . . . . . . . 23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Clutch Replacement . . . . . . . . . . . . . . . . . . . . . . . 24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . 27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Touch-Pad Display . . . . . . . . . . . . . . . . . . . . . . . . 29
Control Board Replacement . . . . . . . . . . . . . . . . . 30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . 33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 34
Forward/Reverse Cable Replacement . . . . . . . . . 35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2
Steering Cable Replacement . . . . . . . . . . . . . . . . 37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Front Wheel Replacement . . . . . . . . . . . . . . . . . . . 40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Parking Brake Service . . . . . . . . . . . . . . . . . . . . . . 41
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Rear Wheel and Wheel Motors . . . . . . . . . . . . . . . 42
Rear Wheel Removal . . . . . . . . . . . . . . . . . . . . 42
Rear Wheel Installation . . . . . . . . . . . . . . . . . . . 42
Wheel Motor Removal . . . . . . . . . . . . . . . . . . . . 42
Wheel Motor Installation . . . . . . . . . . . . . . . . . . 43
Wheel Sensor Replacement . . . . . . . . . . . . . . . 43
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Parts (24U235 Control Panel) . . . . . . . . . . . . . . . . 54
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Parts (Front Wheel) . . . . . . . . . . . . . . . . . . . . . . . . 60
Series A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Series B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Parts List - Series A . . . . . . . . . . . . . . . . . . . . . . 61
Parts List - Series B . . . . . . . . . . . . . . . . . . . . . . 61
Parts (Gun Mount) . . . . . . . . . . . . . . . . . . . . . . . . . 62
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Parts (Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Parts List (Pump) . . . . . . . . . . . . . . . . . . . . . . . . 67
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Wiring Parts List . . . . . . . . . . . . . . . . . . . . . . . . 69
Hydraulic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 70
Hydraulic Parts List . . . . . . . . . . . . . . . . . . . . . . 71
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 72
3A3394E Repair - Parts
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 symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
TRAFFIC HAZARD
Being struck by other vehicles may result in serious injury or death.
• Do not operate in traffic.
• Use appropriate traffic control in all traffic areas.
• Follow local highway and transportation regulations for traffic control (for example: Manual on Uniform Traffic Control Devices, U.S. Department of Transportation).
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent flowing through the equipment can cause static sparking. To help prevent fire and explosion:
• Use equipment only in well ventilated area.
• Do not fill fuel tank while engine is running or hot; shut off engine and let it cool. Fuel is flammable and can
ignite or explode if spilled on hot surface.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths
(potential static arc).
• Ground all equipment in the work area. See Grounding instructions.
• Never spray or flush solvent at high pressure.
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are antistatic or conductive.
• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you
identify and correct the problem.
• Keep a working fire extinguisher in the work area.
SKIN INJECTION HAZARD
High-pressure spray is able to inject toxins into the body and cause serious bodily injury. In the event that
injection occurs, get immediate surgical treatment.
• Do not aim the gun at, or spray any person or animal.
• Keep hands and other body parts away from the discharge. For example, do not try to stop leaks with any
part of the body.
• Always use the nozzle tip guard. Do not spray without nozzle tip guard in place.
• Use Graco nozzle tips.
• Use caution when cleaning and changing nozzle tips. In the case where the nozzle tip clogs while spraying,
follow the Pressure Relief Procedure for turning off the unit and relieving the pressure before removing
the nozzle tip to clean.
• Equipment maintains pressure after power is shut off. Do not leave the equipment energized or under pressure while unattended. Follow the Pressure Relief Procedure when the equipment is unattended or not
in use, and before servicing, cleaning, or removing 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 bleed pressure quickly. Be thoroughly familiar with the controls.
3A3394E Repair - Parts
3
Warnings
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.
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. For complete information about your
material, request Safety Data Sheet (SDS) from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away 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 solvents or fluids
containing such solvents.
• Do not use chlorine bleach.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for
compatibility.
MOVING PARTS HAZARD
Moving parts can pinch, cut 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 and disconnect all power sources.
ENTANGLEMENT HAZARD
Rotating parts can cause serious injury.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Do not wear loose clothing, jewelry or long hair while operating equipment.
• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.
4
3A3394E Repair - Parts
Warnings
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.
• Read Safety Data Sheet (SDS) to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:
• Do not touch hot fluid or equipment.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye
injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited
to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
BATTERY HAZARD
The battery may leak, explode, cause burns, or cause an explosion if mishandled. Contents of an open battery can cause severe irritation and/or chemical burns. If on skin, wash with soap and water. If in eyes, flush
with water for at least 15 minutes and get immediate medical attention.
• Only use the battery type specified for use with the equipment. See Technical Data.
• Replace battery only in well-ventilated area and away from flammable or combustible materials, including
paints and solvents.
• Do not dispose of battery in fire or heat above 50°C (122°F). The battery is capable of exploding.
• Do not throw into fire.
• Do not expose battery to water or rain.
• Do not disassemble, crush, or penetrate the battery.
• Do not use or charge a battery that is cracked or damaged.
• Follow local ordinances and/or regulations for disposal.
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 cause cancer, birth defects or other
reproductive harm. Wash hands after handling.
3A3394E Repair - Parts
5
Warnings
Important Laser Information for Units with Laser Option
LASER LIGHT HAZARD: AVOID DIRECT EYE CONTACT
Eye exposure to Class IIIa/3R levels of laser light can potentially present an eye (retinal) injury hazard, including spot blindness or other retinal injury. To avoid direct eye exposure:
• Never look directly in to a laser beam or point the beam into the eyes of others, even at long distances.
• Never shine the laser at mirror like surfaces which can cause specular reflections of the beam.
• Always set the laser at a height and angle that prevents the beam from shining into people’s eyes.
• Immediately terminate laser emissions if personnel, animals or reflective objects approach the beam.
• Always turn off laser when unattended.
• Do not remove any warning labels from the laser.
• Only properly trained laser operators are to use this product.
• Never allow beams to be aimed toward traffic, vehicles, or heavy equipment. Even when not damaging at
long distances, the high brightness of lasers can distract or disrupt vehicle operations.
• Never point a laser at an aircraft or law enforcement personnel. This is considered a felony in most locations, with the possibility of jail time, heavy fines or both.
• Do not disassemble laser product. Return to factory for all service procedures.
• Laser must be turned OFF when cleaning the lens, so as not to create unwanted laser refraction.
LASER RADIATION HAZARD
Use of controls or adjustments or performance of procedures other than those specified herein may result in
hazardous radiation exposure.
• Do not attempt to open or disassemble the laser housing under any circumstances. Doing so may cause
exposure to potentially hazardous levels of laser radiation.
• No serviceable parts within. Unit is factory sealed.
FIRE AND EXPLOSION HAZARD
Connecting directly to a generator source can create a short or sparking under certain conditions.
• Only connect GL1700 to a dedicated 12 volt DC battery source.
6
3A3394E Repair - Parts
Warnings
Battery Disposal
Do not place batteries in the trash. Recycle batteries according to local regulations. To find a recycling location in the
USA and Canada call 1-800-822-8837 or go to www.call2recycle.org.
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3A3394E Repair - Parts
7
Component Identification (LLV 250DC Shown)
Component Identification (LLV 250DC Shown)
1
Paint filter, both sides
10 Serial label under operator platform
2
Adjustable pad
11 Rear gun arm mount, both sides
3
Engine fuel cap
12 Hydraulic fill cap/dipstick
4
Wheel motor bypass valve
13 Prime/drain valve, both sides
5
Straight line adjuster
14 Handle bar height adjustment knob
6
Gun trigger lock
15 Two paint hoppers (15 gallon/56 liter)
7
Displacement pump, both sides
16 Hydraulic oil filter
8
Brake
17 Front gun mount, both sides
9
Operator platform
18 Steering handle
*LLV 250SPS has only 1 paint hopper and 1 pump.
8
3A3394E Repair - Parts
Component Identification (Controls)
Component Identification (Controls)
1
33
2
1
2
11
4
5
10
9
6
8
7
on
off
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1
Gun trigger control
7
12V accessory jack
2
Gun 1, 2, 3 selector
8
Engine key switch, OFF - ON - Start
3
Display
9
Engine clutch switch
4
Forward/reverse lever
10 Engine choke
5
Pressure control
11 Engine throttle
6
Hydraulic pump valve, both sides
3A3394E Repair - Parts
9
Grounding Procedure (For Flammable Materials Only)
Grounding Procedure
2. Set pump valve(s) to OFF (250SPS has one pump
valve; 250DC has two pump valves). Turn engine OFF.
(For Flammable Materials Only)
This 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.
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1. Position striper so that the tires are not on pavement.
2. Striper is shipped with a grounding clamp. Grounding
clamp must attach to grounded object (e.g. metal sign
post).
3. Turn pressure control to lowest setting. Trigger all guns
to relieve pressure.
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ti3441a
PAINT
4. Engage all gun trigger locks. Turn prime valve(s) down
(250SPS has one prime valve; 250DC has two prime
valves).
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ti23146a
Pressure Relief Procedure
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5. If you suspect the spray tip or hose is clogged or that
pressure has not been fully relieved:
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop dispensing and before
cleaning, checking, or servicing the equipment.
a. VERY SLOWLY loosen the tip guard retaining nut
or the hose end coupling to relieve pressure gradually.
1. Perform Grounding Procedure if using flammable
materials.
c.
10
b. Loosen the nut or coupling completely.
Clear the obstruction in the hose or tip.
3A3394E Repair - Parts
Ground Drive Belt Replacement
Ground Drive Belt
Replacement
Installation
1. Install belt onto pulleys.
Removal
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1. If equipped with a Pressurized Bead System,
remove pressurized bead tanks and compressor,
see Pressurized Bead System manual 332230.
2. Tighten tensioning bolt to move two pulleys apart
and tighten belt to proper tension (see table).
2. Loosen four screws and remove belt cover.
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Ground Drive Belt Tension Recommendations
Tension
53 +/- 2 Lbf (236 +/- 9 N)
Frequency
167 +/- 3 Hz
Tension
45 +/- 2 Lbf (200 +/- 9 N)
Used Belt
Frequency
155 +/- 3 Hz
Gates Sonic Tension Meter
Settings: M = MASS = 85 g/m
W = # of belts = 1
S = Span = 157 mm
New Belt
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3. Loosen two hold-down bolts.
3. Install mounting plate and tighten two hold-down
bolts.
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4. Loosen tension bolt to bring two pulleys closer
together to create slack in the belt.
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4. Replace belt cover and tighten four screws.
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5. Remove belt.
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5. If equipped with a Pressurized Bead System, install
pressurized bead tanks and compressor, see Pressurized Bead System manual 332230.
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3A3394E Repair - Parts
11
Oil Reservoir Belt Replacement
Oil Reservoir Belt
Replacement
Installation
1. Replace belt.
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Removal
NOTE: Ground drive belt must be removed before oil
reservoir belt can be replaced, see Ground Drive Belt
Replacement, page 11.
2. Tighten two adjustment bolts evenly and maintain
belt alignment. Tighten belt to proper tension (see
table).
1. Loosen four hold-down bolts.
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2. Loosen two adjustment bolts to bring pulleys closer
together to create slack in the belt.
Oil Reservoir Belt
Tension Recommendations
Tension
55 +/- 2 Lbf (245 +/- 9 N)
Frequency
114 +/- 2 Hz
Tension
48 +/- 2 Lbf (214 +/- 9 N)
Used Belt
Frequency
106 +/- 2 Hz
Gates Sonic Tension Meter
Settings: M = MASS = 85 g/m
W = # of belts = 1
S = Span = 236 mm
New Belt
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3. Tighten four hold-down bolts.
3. Remove belt.
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12
4. Install Ground Drive Belt and tighten to proper
tension, see Ground Drive Belt Replacement,
page 11.
3A3394E Repair - Parts
Hydraulic System Purging
Hydraulic System
Purging
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop dispensing and before
cleaning, checking, or servicing the equipment.
5. Start engine and run at low speed.
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6. Turn on the Main Power Switch to engage clutch.
Follow this procedure after replacing any hydraulic
component other than the hydraulic gun manifold which
is self-purging.
1. Perform Pressure Relief Procedure, page 10.
2. Set LineStriper on blocks so wheels are off ground.
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3. Fill oil reservoir to “Full” range.
Full Range (cold)
7. Slowly pull forward/reverse control lever in forward
and reverse directions 10 times.
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4. Make sure drive wheel release is closed (+).
+
NOTE: Both rear wheels should turn in the correct
direction. If one wheel is not turning, carefully
restrain the spinning wheel to purge out the wheel
that is not turning.
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3A3394E Repair - Parts
13
Hydraulic System Purging
8. Turn the prime valve down and open the hydraulic
pump valve. Allow the paint pump to stroke 10 times
and then close the hydraulic pump valve.
9. Repeat step 8 for the other pump.
10. The hydraulic gun manifold is self-purging.
11. Use the key switch to turn engine off. Check oil
level. Top off to “Full” range.
Full Range (cold)
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14
3A3394E Repair - Parts
Ground Drive Pump Replacement
Ground Drive Pump
Replacement
5. Disconnect all fittings and hoses from pump (63).
NOTE: Oil will spill out of hoses. Have rags and
waste pail nearby.
6. Remove nut (3) and disconnect tie rod (40) underneath pump (63).
7. Remove two mounting bolts (82) and washers (55)
to remove pump (63) from bracket.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop dispensing and before
cleaning, checking, or servicing the equipment.
Installation
Removal
3. Connect all fittings and hoses to pump (63).
1. Perform Pressure Relief Procedure, page 10.
4. Install key (60) onto pump shaft and slide pulley (64)
onto shaft.
1. Insert pump (63) into bracket (62) and install two
mounting bolts (82) and washers (55).
2. Install tie rod (40) with nut (3) to lever underneath
pump (63).
2. Remove ground drive belt, see Ground Drive Belt
Replacement, page 11.
5. Align pulley to outer clutch groove and tighten two
set screws (71).
3. Use allen wrench to remove two set screws (71)
from pulley (64).
6. Install ground drive belt and tighten to proper tension,
see Ground Drive Belt Replacement, page 11.
4. Slide pulley (64) off shaft and save key (60).
71
60
63
71
64
62
3
55
ti19135a
82
40
3A3394E Repair - Parts
15
Oil Reservoir Pump Replacement
Oil Reservoir Pump
Replacement
5. Loosen two set screws and cable.
ti19142a
6. Remove eight screws and oil reservoir cover with
pump.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop dispensing and before
cleaning, checking, or servicing the equipment.
Removal
1. Perform Pressure Relief Procedure, page 10.
2. Remove belt cover, see Oil Reservoir Belt
Replacement, page 12.
3. Remove oil filter and disconnect five hydraulic hoses
from oil reservoir.
ti23902a
7. Remove pulley from pump. Remove four screws and
pump from reservoir cover.
ti23901a
4. Loosen nut and slide cable sleeve down to gain
access to the two cable set screws.
ti19672a
ti19144a
16
3A3394E Repair - Parts
Oil Reservoir Pump Replacement
Installation
1. Install pump onto oil reservoir cover with four
screws. Make sure the five o-rings are in place.
3. Install pulley on pump shaft and maintain belt alignment to inner groove of the clutch pulley. Tighten
two pulley screws.
ti19670a
ti19671a
2. If hydraulic oil is contaminated in reservoir, drain
reservoir and remove contamination. Install oil
reservoir cover with eight screws to the oil reservoir
base.
4. Turn pressure control knob clockwise until seated.
ti23905a
5. Turn hydraulic pump pressure control clockwise
until seated then counterclockwise 1/6 turn.
ti23904a
ti23906a
3A3394E Repair - Parts
17
Oil Reservoir Pump Replacement
6. Install cable and tighten two set screws.
8. Connect five hydraulic hoses to fittings on oil
reservoir. Replace oil filter.
ti19143b
7. Slide cable sleeve up and tighten screw.
ti19145a
ti23901a
9. Install and tension belts, see Oil Reservoir Belt
Replacement, page 12 and Ground Drive Belt
Replacement, page 11.
10. Fill reservoir and purge hydraulic system, see
Hydraulic System Purging, page 13.
18
3A3394E Repair - Parts
Hydraulic Gun Manifold Replacement
Hydraulic Gun Manifold
Replacement
ti19164a
Removal
1. Remove tank lid(s) and siphon tube(s).
5. Label wire harnesses GUN 1, GUN 2, and GUN 3.
Disconnect three wire harnesses from solenoids.
Gun 3
Gun 2
Gun 1
LL250DC shown
2. Remove tank(s) from unit.
3. Remove six screws and then remove front shield
from unit.
ti23909a
6. Label gun cables GUN 1, GUN 2, and GUN 3. Disconnect gun cables from actuators.
Gun #
ti19163a
ti19159a
4. Remove four screws and pad.
3A3394E Repair - Parts
19
Hydraulic Gun Manifold Replacement
7. Use a needle-nose pliers to remove gun cables from
bracket.
Installation
1. Slide hydraulic manifold in and up into unit. Install
and tighten two mounting bolts.
ti23911a
8. Use wrench to disconnect manifold tubes by the
paint pump. NOTE: Oil will spill. Use a rag to contain the oil.
ti23914a
2. Loosely install manifold tubes to manifold.
3. Loosely install manifold tubes by the paint pump.
Tighten four nuts.
ti23912a
9. Disconnect manifold tubes at manifold.
10. Remove two mounting bolts and slide hydraulic
manifold down and out from unit.
ti23915a
ti23913a
20
3A3394E Repair - Parts
Hydraulic Gun Manifold Replacement
4. Observe label on bracket. Push labeled gun cables
into manifold brackets.
6. Connect three wire harnesses to solenoids.
Gun 3
Gun 2
Gun 1
ti23916a
7. Install pad and tighten four screws.
ti23964a
5. Connect gun cables to actuators.
8. Install front shield to unit and tighten six screws.
9. Install tank(s), lid(s) and insert siphon tube(s) into
tank(s).
NOTE: The hydraulic gun manifold is self-purging.
ti19159a
3A3394E Repair - Parts
21
Paint Pump Replacement
Paint Pump Replacement
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop dispensing and before
cleaning, checking, or servicing the equipment.
115
116
Removal
1. Perform Pressure Relief Procedure, page 10.
2. Disconnect suction tube (120).
104
3. Disconnect hose (123) and fitting (95) from paint
pump (107). Note orientation of fitting (95) for installation.
106
4. Remove screw (115), nut (116) and pump guard
(114).
105
5. Use hammer to loosen pump jam nut (106).
6. Slide down retainer (104) and remove pin (105).
114
7. Unscrew and remove paint pump (107).
Installation
95
107
1. Extend pump rod out of pump (107).
2. Insert pump rod into hydraulic motor rod and install
pin (105) and retainer (104).
123
3. Thread pump (107) into hydraulic motor housing
until pump bottoms out. Unscrew pump one full turn
and orient pump outlet as noted in Removal step 3.
4. Use hammer to tighten pump jam nut (106).
120
5. Install guard (114) with screw (115) and nut (116).
6. Install fitting (95) and connect hose (123).
ti19138b
7. Connect suction tube (120).
22
3A3394E Repair - Parts
Hydraulic Motor Replacement
Hydraulic Motor
Replacement
Installation
1. Install hydraulic motor with four mounting bolts (116).
NOTICE
Use a screwdriver to lift pump piston up to gain access
to mounting bolts and avoid contact with piston. Contact with pump mounting bolts can scratch and damage
the pump piston.
2. Install pump counter (112) with two screws (113).
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop dispensing and before
cleaning, checking, or servicing the equipment.
3. Connect hose (74) or tube (98) to fitting.
4. Connect fitting (108) above ball valve (109).
5. Install paint pump, see Paint Pump Replacement,
page 22.
6. Purge hydraulic system, see Hydraulic System
Purging, page 13.
Removal
1. Perform Pressure Relief Procedure, page 10.
2. Remove paint pump, see Paint Pump Replacement, page 22.
3. Disconnect fitting (108) above ball valve (109).
NOTE: Oil will spill out of hoses. Have rags and
waste pail nearby.
4. Disconnect hose (74) for pump 1 or tube (98) for
pump 2.
5. Disconnect pump counter (112) with 2 screws (113).
NOTICE
74
98
Use a screwdriver to lift pump piston up to gain access
to mounting bolts and avoid contact with piston. Contact with pump mounting bolts can scratch and damage
the pump piston.
6. Remove four mounting bolts (116) from hydraulic
motor and remove motor from sprayer.
108
112
113
109
116
ti23917a
3A3394E Repair - Parts
23
Clutch Replacement
Clutch Replacement
6. Remove three bolts (81) and pulley (61).
61
81
Removal
1. Remove ground drive belt, page Ground Drive Belt
Replacement, page 11.
2. Remove oil reservoir belt, see Oil Reservoir Belt
Replacement, page 12.
ti19216a
7. Remove engine recoil starter and place a screwdriver through the recoil starter cup.
3. Remove two hold-down bolts for the ground drive
pump bracket.
ti19696a
ti19215a
4. Unscrew tensioning bolt from the ground drive pump
bracket.
ti19131a
ti19697a
5. Move ground drive pump assembly aside.
8. Remove center bolt (59) and remove clutch (57).
57
58
ti19213a
56
60
59
ti19214a
24
3A3394E Repair - Parts
Clutch Replacement
9. Disconnect clutch connector to main wire harness.
58
59
ti19692a
ti19212a
4. Install pulley (61) and torque three screws (81) to 10
ft-lb (13 N•m).
Installation
1. Install spacer (56) and key (60) onto crankshaft.
Slide clutch (57) onto crankshaft.
57
58
56
61
81
60
ti19216a
5. Install recoil starter onto engine.
59
ti19214a
2. Align clutch and wire in bracket.
ti23918a
ti19211a
3. Install heavy washer (58) and bolt (59) onto crankshaft. Torque bolt to 45 +/- 5 ft-lb (61 +/- 7 N•m). Use
screwdriver in recoil starter cup to hold crankshaft.
3A3394E Repair - Parts
25
Clutch Replacement
6. Connect clutch to wire harness.
ti19212a
7. Install ground drive pump assembly with tensioning
and two hold-down bolts.
ti19908a
8. Install and tension belts, see Oil Reservoir Belt
Replacement, page 12 and Ground Drive Belt
Replacement, page 11.
26
3A3394E Repair - Parts
Engine Replacement
Engine Replacement
5. Disconnect throttle cable.
Removal
1. Remove clutch, see Clutch Replacement, page 24.
ti19183a
NOTICE
6. Disconnect choke cable.
To reduce the risk of battery damage and shorts,
always disconnect NEGATIVE (black wire) first.
2. Disconnect two negative (black) battery wires at battery. Negative battery post is located above platform
on the left side.
3. Disconnect seven wires from engine.
ti19185a
7. Remove four mounting bolts from engine.
Engine Ground
Ignition
Voltage Regulator
Starter Solenoid
Battery
ti23921
ti19187a
4. Remove air filter cover, element and base.
8. Remove engine. NOTE: Engine voltage regulator is
located below engine mounting plate. Remove two
screws and disconnect wires.
ti19703a
ti19186a
3A3394E Repair - Parts
27
Engine Replacement
Installation
4. Install throttle cable.
a. Place speed lever to high speed.
1. Install engine voltage regulator below engine
mounting plate with two screws. Connect regulator
to wire harness.
b. Insert “Z” bend wire into hole furthest from pivot.
c.
Place cable sheathing under clamp and pull
cable against high speed stop screw.
d. Tighten screw on cable clamp.
e. Verify proper operation of speed lever.
ti19706a
2. Install engine and tighten four mounting bolts and
nuts.
ti19690a
5. Install air filter base, element and cover.
ti19187a
3. Install choke cable:
a. Make sure choke knob is pressed down.
b. Insert choke cable wire into hex-shaped pivot.
c.
Insert cable sheathing under cable clamp and
tighten screw.
ti19186a
6. Connect seven wires to engine.
d. Tighten screw on hex-shaped pivot.
e. Verify proper operation of engine choke.
Engine Ground
Ignition
Voltage Regulator
Starter Solenoid
Battery
ti19686a
ti23921
7. Install clutch, see Clutch Replacement, page 24.
8. Connect two negative (black) wires at battery.
9. Add gas and oil to engine (see Operation manual).
10. Start engine and verify high speed of 3600 rpm.
28
3A3394E Repair - Parts
Touch-Pad Display
Touch-Pad Display
1
3
2
1
3
ti23924a
NOTICE
To avoid electrostatic-discharge (ESD) always use wrist
strap 112190 when servicing the touch-pad display.
1. Toggle switch kit.
a. Torque screws to 3-5 in-lb (0.34-0.56 N•m)
b. Torque nuts to 3-5 in-lb (0.34-0.56 N•m)
2. Display kit. Remove protective film from display
face.
a. Torque screws to 3-5 in-lb (0.34-0.56 N•m)
3. Membrane switch kit.
a. Torque screws to 1-2 in-lb (0.11-0.23 N•m)
3A3394E Repair - Parts
29
Control Board Replacement
Control Board
Replacement
5. Remove four screws and remove pad.
Removal
1. To disconnect power remove fuse, see Fuse
Replacement, page 34.
2. Remove siphon tube(s) and lid(s).
ti23930a
6. Remove six screws and control shroud.
LL250DC Shown
3. Remove tank(s) from unit.
4. Remove six screws and then remove front shield
from unit.
ti19163a
ti23931a
30
3A3394E Repair - Parts
Control Board Replacement
3. Connect all wires to control board. See, Wiring Diagram, page 68. Pump number 1 is on the left when
you stand in the operator position.
7. Remove two screws and splash shield.
4. Bundle and secure wires with a cable tie just
inboard of the choke cable.
5. Bundle and secure wires with a cable tie just outboard of the key switch.
6. Install fuse, see Fuse Replacement, page 34.
Check control, switches and display.
7. Install splash shield with two screws.
ti24973a
8. Disconnect all wires from control board.
9. Remove eight control board mounting screws and
then remove control board.
ti2376a
8. Install control shroud with six screws. See Removal
step 6.
9. Install pad and tighten four screws.
ti24074a
Installation
1. Install control board with eight mounting screws.
ti24075a
2. Before connecting wires to control board, make sure
that all wires are routed above the two steering
cables.
3A3394E Repair - Parts
ti23930a
31
Control Board Replacement
10. Install front shield and tighten six screws.
11. Install tank(s), lid(s) and siphon tube(s).
ti19200a
12. If control board was replaced select language, units,
and calibrate distance sensor (see Operation
manual).
32
3A3394E Repair - Parts
Battery Replacement
Battery Replacement
Installation
NOTICE
To reduce the risk of battery damage and shorts,
always connect NEGATIVE (black wire) last.
Removal
1. Place battery on operator platform. Connect two red
wires to positive (+) post of the battery.
1. Battery may be removed from the back of the unit by
sliding it out above the operator platform.
2. Loosen straps and move coiled hoses above the
operators platform.
3. Loosen hold down strap from battery.
NOTICE
To reduce the risk of battery damage and shorts,
always disconnect NEGATIVE (black wire) first.
4. Disconnect two black wires from battery.
ti24078a
2. Pickup and slide battery into mounting position.
Install battery hold down strap.
3. Connect two black wires to negative (–) post of the
battery.
ti24079a
5. Lift battery and slide it back onto the platform. Disconnect two red wires from battery.
ti24104a
4. Place coiled paint hoses over bracket and secure
with straps.
ti24077a
6. Remove battery.
3A3394E Repair - Parts
33
Fuse Replacement
Fuse Replacement
1. Remove fuse cover.
4. Use needle-nose pliers to install new fuse.
2. Use needle-nose pliers to remove old fuse and
inspect it for an open circuit.
5. Replace cover.
3. If fuse is open, a wire has shorted to the frame or auxiliary lighting requires too much power. Check wiring
or reduce auxiliary lighting before replacing fuse.
ti23941a
34
3A3394E Repair - Parts
Forward/Reverse Cable Replacement
Forward/Reverse Cable
Replacement
Removal
1. If equipped with a Pressurized Bead System,
remove pressurized bead tanks and compressor.
See Pressurized Bead System manual 332230.
2. Remove tank lids and siphon tubes.
ti19128a
6. At the handlebar, remove locknut (3) and ball joint
(40) from handlebar forward/reverse lever. Remove
ball joint (40) from cable (148) and save if not
replacing. Loosen two nuts on cable (148) and
remove from bracket.
40
3
148
ti23942a
3. Remove tanks from unit.
4. Remove six screws and front shield from unit.
7. At the ground drive pump, remove locknut (3) and
ball joint (40) from ground drive pump. Remove ball
joint from cable and save if not replacing. Loosen two
nuts on cable (148) and remove from bracket (62).
62
3
148
ti19163a
5. Loosen four screws and remove belt cover.
40
ti19700a
8. Install new cable (148) as old cable is removed to
follow same route through frame.
3A3394E Repair - Parts
35
Forward/Reverse Cable Replacement
Installation
4. Verify that the handlebar forward/reverse lever does
not touch handlebar grips. Adjust cable and ball
joints if needed.
1. Install new cable (148) by following same route as
old cable is being removed.
5. Install belt cover and tighten four screws.
2. At ground drive pump bracket (62), install cable
(148) in bracket slot and tighten two nuts. Install ball
joint (40) onto cable and attach ball joint (40) to
ground drive pump with locknut (3).
6. Install front shield onto unit and tighten the six
screws.
7. Install tanks onto unit.
8. Install siphon tubes and tank lids.
9. If equipped with a Pressurized Bead System, install
pressurized bead tanks and compressor. See Pressurized Bead System manual 332230.
62
3
148
40
ti19700a
3. Install cable (148) into handlebar bracket and
tighten two nuts. Install ball joint (40) onto cable.
Install ball joint into handlebar forward/reverse lever
and tighten locknut (3).
40
3
148
ti23942a
36
3A3394E Repair - Parts
Steering Cable Replacement
Steering Cable Replacement
Removal
2. Remove six screws and control shroud.
1. Loosen four screws and remove pad.
ti23930a
ti23931a
3A3394E Repair - Parts
37
Steering Cable Replacement
5. On front wheel fork, remove locknut (3) and ball joint
(40) from fork. Remove ball joint (40) from cable (48)
and save if not replacing. Loosen two nuts on cable
(48) and remove from bracket.
3. Apply parking brake. Raise front wheel off the
ground and support frame on two jack stands.
48
40
3
ti19698a
6. Note position of cable (48) and cut off all cable ties
that retain cable to frame. Install new cable as old
cable is removed to follow same route through
frame.
ti23943a
4. At the handlebar, remove locknut (3) and ball joint
(40) from handlebar. Remove ball joint (40) from
cable (48) and save if not replacing. Loosen two
nuts on cable (48) and remove from bracket.
3
48
40
ti23944a
38
3A3394E Repair - Parts
Steering Cable Replacement
Installation
1. Install new cable (48) by following same route as old
cable is being removed.
2. At front wheel, adjust front nut on cable (48) to
match the threads on the other side of front fork.
Install cable (48) into frame bracket and tighten rear
nut.
Adjust to match
other side
of front fork
5. Install ball joint (40) onto cable (48) and match
threads on other side of handlebar. Install ball joint
(40) into handlebar and tighten locknut (3).
3
48
40
ti19685a
3. Install ball joint (40) onto cable (48) and match
threads on other side of front fork. Install ball joint
(40) into fork and tighten locknut (3).
48
40
ti23944a
6. Verify that handlebar is aligned straight with frame.
If misaligned, adjust nuts on cable (48) to straighten
handlebar to frame.
3
ti19698a
4. At handlebar, adjust front nut on cable (48) to match
threads on other side of handlebar. Install cable (48)
into bracket and tighten rear nut.
7. At handlebar, loosen front nut on each cable (48) by
three full rotations. Tighten rear nut on both cables
three full rotations. Verify both front and rear nuts
are tight against bracket.
Adjust to match
other side
of handlebar
ti19685a
8. Verify that front wheel self-centers and that steering
is tight and responsive. Ball joint (40) should rotate
easily on the ball. If needed, remove ball joint from
fork and adjust ball joint on cable (48).
9. Install pad and tighten four screws.
10. Remove jack stands and test drive sprayer to check
steering. Adjust if needed. Install cable ties in locations noted in step 6 of Removal.
11. Verify straight line tracking and adjust if necessary
(see Operation manual).
12. Install control shroud and tighten six screws.
3A3394E Repair - Parts
39
Front Wheel Replacement
Front Wheel Replacement
Removal
Installation
1. Apply parking brake. Raise front wheel off ground
and support frame on two jack stands.
1. Insert two spacers (36) into wheel (35) and slide into
fork (34).
34
39
ti19693a
37
36
ti20125a
2. Remove locknut (39) from axle bolt (37) and remove
axle bolt (37) from fork (34).
36
35
2. Insert axle bolt (37) through fork (34), spacers (36)
and wheel (35).
34
39
3. Tighten locknut (39) onto axle bolt (37).
NOTE: When properly tightened, the wheel should
not wobble to the left or right and should stop
coasting quickly.
4. Remove jack stands and test drive sprayer to verify
straight line tracking. Adjust if necessary (see Operation manual).
37
36
ti20125a
36
35
3. Remove two spacers (36) and wheel (35) from fork
(34).
40
3A3394E Repair - Parts
Parking Brake Service
Parking Brake Service
Removal
Installation
1. Remove tire, wheel hub, and fender. See, Wheel
Motor Removal, page 42.
1. Install lever (14) with pin (B) and clip (13).
2. Remove clips (13) from three pins (A). Remove pins
and levers.
3. Use screwdriver to remove spring (15). Remove clip
(13) and pin (B).
4. Replace damaged or worn parts.
3A3394E Repair - Parts
2. Use screwdriver to install spring (15).
3. Install levers (10, 16) with three pins (A) and clips
(13).
4. Install fender, wheel hub, and tire. See, Wheel
Motor Removal, page 42.
5. Adjust screw (17) to hold tire when brake lever (16)
is depressed.
41
Rear Wheel and Wheel Motors
Rear Wheel and Wheel Motors
Rear Wheel Removal
3. Inflate rear tires to 55 +/- 5 psi (380 +/- 34 kPa).
1. Set LineStriper on blocks so wheels are off ground.
Wheel Motor Removal
1. Place jack under frame near wheel and raise jack.
2. Remove four lug nuts (22) and wheel (16).
16
ti18587a
2. Remove four lug nuts (22) and wheel (16).
22
16
ti18589a
3. Remove pin (56), castle nut (21b) and wheel hub
(22b). Wheel hub may require a wheel puller; not
supplied by Graco.
22
6
112
ti18589a
5
79
4
Rear Wheel Installation
1. Replace wheel and install lug nuts. Alternately
tighten lug nuts opposite of each other.
2. Tilt LineStriper on side and remove blocks.
21a
78
22b
19
21b
56
ti23945a
4. Remove screw (6) and distance sensor (4) with
clamp (5).
5. Remove four bolts (78), lock nuts (79) from fender
(19).
ti18588a
42
6. Disconnect two hydraulic hoses (112) from wheel
motor (21a) and remove wheel motor.
3A3394E Repair - Parts
Rear Wheel and Wheel Motors
Wheel Motor Installation
1. Connect two hydraulic hoses (112) to wheel motor
(21a) and insert wheel motor (21a) into frame (1).
2. Install wheel motor (21a) and fender (19) with four
bolts (78) and lock nuts (79).
3. Install distance sensor (4) and clamp (5) with screw
(6) on to fender (19).
6
112
5
79
4
21a
78
22b
ti23930a
19
21b
2. Place jack under frame on the side opposite of the
brake and raise jack.
56
ti23945a
4. Install wheel hub (22b), castle nut (21b), and pin
(56).
5. Install wheel (16) and four lug nuts (22). Alternately
tighten lug nuts opposite each other.
3. Remove four lug nuts (22) and wheel (16).
16
22
16
ti18589a
4. Disconnect wheel sensor connector from wire harness.
22
ti18589a
6. Purge hydraulic system. See Hydraulic System
Purging, page 13.
Wheel Sensor Replacement
Removal
1. Loosen four screws and remove pad.
ti19328b
5. Use wrench to remove screw (6), clamp (5), and
wheel sensor (4).
3A3394E Repair - Parts
43
Rear Wheel and Wheel Motors
6
ti18564a
ti19329a
5
NOTE: Sensor is working properly if the measure
display reads 12.3 to 12.7 ft (3.75 to 3.87 m).
5. Install wheel (16) and four lug nuts (22).
16
4
ti23946a
22
Installation
ti18589a
1. Install wheel sensor (4) and clamp (5) with screw
(6). See Removal step 5.
2. Connect wheel sensor connector to wire harness.
6. Lower jack.
7. Install pad and tighten four screws.
ti19328b
3. Verify sensor is working by turning on the main
power switch and press
MEASURE screen.
to display the
ti23930a
4. Press gun trigger control button and rotate hub by
hand exactly three turns.
44
8. Calibrate sprayer. See Operation manual.
3A3394E Repair - Parts
Troubleshooting
Troubleshooting
General
Problem
Cause
Battery is discharged.
Engine will not crank
Engine cranks slow
Engine will not start
High engine speed at no load
Machine will not drive
3A3394E Repair - Parts
Key switch is defective.
Main wire harness is defective.
Excessive hydraulic load. Engine clutch switch
is on.
Engine is out of gas.
Fuel shut-off lever is OFF.
Solution
Turn key switch to ON. Choke engine and pull recoil
starter rope.
Replace key switch.
Replace wire harness, see Wiring Diagram, page 68.
Turn engine clutch switch OFF.
Refill gas tank. See engine manual.
Move fuel shut-off lever to ON position.
Check oil level and add oil if necessary. See engine
Engine oil level is low.
manual.
Engine is cold.
Use engine choke.
Spark plug cable is disconnected or damaged. Connect spark plug cable or replace spark plug cable.
Key switch is defective.
Replace key switch.
Main wire harness is disconnected or defective. Reconnect or replace main wire harness
Improperly adjusted high speed setting.
Reset high speed to 3600 - 3700 engine rpm at no load.
Worn engine governor.
Adjust or replace engine governor.
Engine clutch switch is OFF.
Turn engine clutch switch ON.
Close wheel motor bypass valve to engage drive. See
Hydrostatic drive bypass valve is open.
Operation manual
Hydraulic fluid is low.
Shut off striper and add fluid*.
Drive cable is disconnected or broken.
Reconnect or replace cable.
Reconnect or replace harness as
Clutch wire harness is disconnected or broken.
necessary.
Clutch does not work.
Replace clutch.
Ground drive belt is worn or broken.
Adjust or replace ground drive belt.
Ground Drive Pump is worn or not working.
Replace ground drive pump.
Wheel motor(s) worn or not working.
Replace wheel motor.
45
Troubleshooting
Problem
Cause
Engine clutch switch is OFF.
Pump ball valve is OFF.
Pressure setting is too low.
Engine operates, but
displacement pump does
not operate
Prime/drain valve is closed and system
is pressurized.
Hydraulic fluid too low.
Oil reservoir belt is worn, broken, or off
the pulley.
Tip is clogged.
Displacement pump piston rod is stuck due to
dried paint.
Hydraulic motor not shifting.
Displacement pump operates, but
output is low on upstroke
Piston ball is not seating.
Piston packings are worn or damaged.
Suction tube strainer is clogged.
Suction tube air leak.
Pressure setting is too low.
Fluid filter or tip is clogged or dirty.
Solution
Turn engine clutch switch ON.
Turn pump ball valve ON.
Turn pressure adjusting knob clockwise to increase
pressure. See Operation manual.
Open prime/drain valve.
Shut off sprayer. Add fluid*.
Replace oil reservoir belt, see Oil Reservoir Belt
Replacement, page 12.
Reverse tip to clean. See Operation manual.
Repair pump. See Pump manual.
Set pump valve OFF. Turn pressure down. Turn engine
OFF. Pry rod up or down until hydraulic motor shifts.
Service piston ball. See Pump manual.
Replace packings. See Pump manual.
Clean strainer.
Tighten suction tube.
Increase pressure. See Operation manual.
Clean filter and tip. See Operation manual or gun
manual.
Increase throttle setting. See Operation manual.
Engine speed is too low.
Intake valve ball is packed with material or is not
Displacement pump operates but output
Clean intake valve. See Pump manual.
seating properly.
is low on downstroke and/or on both
Pump packings are worn or damaged.
Replace pump packings. See Pump manual.
sides
Use larger diameter hose and/or reduce overall length of
Large pressure drop in hose with heavy
hose. Use of more than 100 ft x 1/4 in. hose significantly
materials.
reduces performance of sprayer. Use 3/8 in. hose for
optimum performance.
Oil reservoir hydraulic filter is dirty or clogged. Change hydraulic filter and hydraulic oil.
Intake line to pump inlet is not tight.
Tighten intake line to pump inlet.
Hydraulic motor is worn or damaged.
Bring sprayer to Graco distributor for repair.
Suction tube strainer is clogged.
Clean strainer
Suction tube air leak.
Tighten suction tube
Drain line to paint hopper is clogged.
Clean drain line
Clean intake valve. Be sure ball seat is not nicked or
Intake valve is leaking.
worn and that ball seats well. Reassemble valve.
Pump is difficult to prime
Pump packings are worn.
Replace pump packings. See Pump manual.
Paint is too thick.
Thin the paint according to supplier recommendations.
Decrease throttle setting before priming pump. See
Engine speed is too high.
Operation manual.
Turn pressure adjusting knob clockwise to increase
Pressure setting too low.
pressure. See Operation manual.
Low stall or run pressure shown on
Pump break-in period takes up to 100 gallons
display
New pump or new packings.
of material.
Faulty transducer.
Replace transducer.
46
3A3394E Repair - Parts
Troubleshooting
Problem
Excessive paint leakage into throat
packing nut
Cause
Throat packing nut is loose.
Throat packings are worn or damaged.
Displacement rod is worn or damaged.
Air in pump or hose.
Fluid is spitting from gun
Tip is partially clogged.
Fluid supply is low or empty.
Excessive leakage around hydraulic
motor piston rod wiper
Sprayer overheats
Excessive hydraulic pump noise
Display does not turn on
Gallon (liter) counter not
adding fluid volume
Remove throat packing nut spacer. Tighten throat
packing nut just enough to stop leakage.
Replace packings. See Pump manual.
Replace rod. See Pump manual.
Check and tighten all fluid connections. Reprime pump.
See Operation manual.
Clear tip. See Gun manual.
Refill fluid supply. Prime pump. See Operation manual.
Check fluid supply often to prevent running pump dry.
Piston rod seal worn or damaged.
Replace hydraulic motor piston rod wiper and seal.
Paint buildup on hydraulic components.
Hydraulic oil level is low.
Low hydraulic fluid level.
Pulleys loose on hydraulic pumps.
Key switch is not turned on.
Main fuse is blown.
Cable between display and main board is
disconnected or damaged.
Display board failure.
Fluid pressure not high enough.
Broken or disconnected pump counter wire,
both pumps.
Clean hydraulic components.
Fill with hydraulic oil. See Operation manual.
Shut off sprayer. Add fluid*.
Remove belt guard. Check and tighten loose pulley.
Turn key switch to ON position.
Replace fuse. See Fuse Replacement, page 34.
Missing or damaged magnet, both pumps.
Bad sensor, both pumps.
Machine not calibrated.
Rear tire pressure is too low or too high.
Distance not adding properly
Gear teeth missing or damaged
(MEASURE mode will be inaccurate and
(right side when standing on platform).
speed will be wrong)
Distance sensor is loose or broken.
Mils not calculating or calculates wrong
Distance sensor.
Gallon counter.
Line width not entered.
Bad or damaged display board.
Pressure control knob does not rotate
Knob is jammed.
Set screw at hydraulic pump connection is
Pressure control knob rotates freely with loose.
no pressure change
Remote cable is broken or disconnected.
3A3394E Repair - Parts
Solution
Reconnect or replace cable.
Replace display board.
Must be over 800 psi (55 bar) for counter to add.
Check wires and connections. Replace any broken
wires.
Reposition or replace magnet on pump, see Parts manual (Pump parts) for magnet location.
Replace sensor. See Hydraulic Motor Replacement,
page 23.
Perform calibration procedure. See Operation manual.
Adjust tire pressure to 55 +/- 5 psi (380 +/- 34 kPa).
Replace distance gear/wheel hub. See Rear Wheel and
Wheel Motors, page 42.
Reconnect or replace sensor. See Wheel Sensor
Replacement, page 43.
See “Distance not adding properly”.
See “Gallon (liter) counter not adding fluid volume”.
Set line width for each gun. See Operation manual.
Replace display board.
Pull back cover where remote cable connects to hydraulic pump and turn counter-clockwise (ccw) until free.
Remove cover and adjust cable. See Oil Reservoir
Pump Replacement, page 16 step 4.
Replace or reconnect cable. See Oil Reservoir Pump
Replacement, page 16 step 4.
47
Troubleshooting
Problem
Cause
Engine clutch switch is not turned ON.
Gun selector switch is OFF.
Display is in AUTO MODE and speed is less
than 0.7 mph (1.1 kph).
Gun does not trigger
Gun triggering is slow
System pressure is too low.
Gun cable is disconnected or broken.
Disconnected or broken wires from control
board to solenoid.
Gun cable is pinched or kinked.
System pressure is too low.
Solution
Turn engine clutch switch ON.
Turn gun selector switch ON.
Increase ground speed to be greater than 0.7 mph
(1.1 kph).
Increase fluid pressure up to at least
1000 psi.
Reconnect or replace cable.
Reconnect or replace wires.
Change gun cable routing or replace cable.
Increase fluid pressure up to at least 1000 psi.
AUTO Mode
Line spacing is not accurate
Gun does not trigger
Wrong line pattern loaded
Machine not calibrated
See Gun Does Not Trigger, page 48.
Reload the correct pattern.
Perform calibration routine (see Operation manual).
PARKING LAYOUT Mode
Gun selector switch is OFF
Turn gun selector switch ON.
Dot size setting is too small
Increase dot size.
Pressure is too low
Increase pressure to 1000 psi.
* Use only Graco approved hydraulic fluid 169236 (5 gallons / 18.9 liter) or 207428 (1 gallon / 3.8 liter)
Gun does not apply dots
48
3A3394E Repair - Parts
Notes
Notes
3A3394E Repair - Parts
49
Parts
Parts
193
189b
189a
191
189
192
6
*179
194
*102
*100 55
*99
189c 191
248
334
235
234
335
*179
261 190
236
149
223
199
336
179
278
100
102
186
179
179
80
204
55
226
52
167
122
144
124
8
145
223 222 220 273
7
200
101
185
179
33
238
239
161
237
187
274
116
264
265
151
150
*LLV 250DC only
50
188
ti23185c
3A3394E Repair - Parts
Parts
Parts List
Ref.
Part
Description
6
7
8
33
52
55
80
99
260212
16M279
100101
101566
111145
100023
120721
16W544
100
16M717
101
102
116
122
111801
107210
102040
SCREW, hex washer hd, thd form
BUMPER, platform
SCREW, cap, hex hd
NUT, lock
KNOB, pronged
WASHER, flat
SCREW, cap, 3/8-16, hexhd
BRACKET, mount, second pump,
LL250, paint
BRACKET, mount, pump, LL250,
paint
SCREW, cap, hex hd
SCREW
NUT, lock, hex
*191239
**124884
108851
126108
24L909
278421
115753
801972
118444
24D618
111192
290159
114271
237686
126071
16W372
HOSE, coupled 3/8 x 11 ft
HOSE, coupled 3/8 x 22 ft
124
WASHER, flat
144
SCREW, shoulder, skt hd
145
FRAME, platform, painted, LL250
149
PAD, foam
150
BATTERY, 33 AH, sealed
151
PAD, battery
161
SCREW, mach, slot hex wash hd
167
PIN, handle, Grindlazer
179
SCREW, cap flang hd
185
LABEL, reflective
186
STRAP, retaining
187
WIRE, ground assembly w/ clamp
188
STRAP, battery
189
MANIFOLD, hydraulic, three piston
189a 24N577 KIT, repair, coil, hydraulic
manifold
189b 24N490 KIT, repair, solenoid
(includes 189a)
3A3394E Repair - Parts
Qty.
4
1
2
2
2
6
2
1
2
1
8
1
2
1
2
2
1
1
1
1
1
1
12
1
2
1
1
1
1
1
Ref.
Part
Description
189c 24V560 KIT, repair, actuator, piston
(includes 234, 235, 236, 334, 335,
336)
190 16W373 BRACKET, manifold, hydraulic,
gun
191 116829 FITTING, 90 degree
192 15C753 SCREW, mach, hex wash hd
193 24M625 TUBE, supply, hydraulic
194 24M626 TUBE, supply, hydraulic
199 24N492 KIT, repair, gun cable
(includes 236)
200 16N380 BRACKET, pin ramp
204 196177 ADAPTER, nipple
220 16X078 HARNESS, wire
222 16N541 WIRE, negative battery
223 16N540 HARNESS, light connection
226 245798 KIT, repair, hose
234 16W656 BUSHING, manifold, cable, gun
235 16W655 ADAPTER, manifold, cable, gun
236 126111 RETAINER, circlip, external, 8mm
237 126095 HOLDER, fuse
238 126096 FUSE, 30A
239 126097 COVER, fuse holder
248 110963 SCREW, cap, flange head
261 16Y454 LABEL, gun indicator
264 801958 PROTECTOR, terminal, red
265 801959 TERMINAL, protector, black
273 558685 WASHER, 1/4 external tooth lock
274 110755 WASHER, plain
278 16P138 LABEL, energy source
334 16P450 BELLOWS, constant volume
335 105510 WASHER, lock, spring, (hi collar)
336 126242 SCREW, cap, sch
Qty.
1
1
2
2
1
1
1
1
2
1
1
1
3
3
3
6
1
1
1
4
1
1
1
1
1
2
3
3
3
* LLV 250DC
** LLV 250SPS
51
Parts
Parts
301
303
302
305
304
301
21
138 87
32
28 24
26
303
25 34
29 22
88 137
23
99
205
36
90
206
135
135
33
39
207
33
211
30
98
212
89
90
36
40
160
3
40
97
3
136
148
27
37
52
263
161
214
169
(See Page 8)
48
86
131
168
184
85
284
283
141
178
ti23186a
52
275
83
3A3394E Repair - Parts
Parts
Parts List
Ref.
Part
Description
3
21
22
23
24
25
26
27
28
29
30
31
32
102393
116424
100022
102040
115480
118886
108868
127372
159346
16X072
24U233
24U234
17B211
33
34
36
37
39
40
48
52
83
85
86
116477
116038
193658
113471
112405
125792
16M273
111145
113677
107257
24N494
87
88
89
90
97
98
24L900
120151
113485
115503
119569
119554
NUT, lock
NUT
SCREW, cap, hex hd
NUT, lock
KNOB, T-handle
GROMMET, isolator
CLAMP
BUSHING
WASHER
BRACKET, control, mount
CABLE, 18 conductor
BOX, control
COVER, control box, LL250,
painted
WASHER, flat, nylon
WASHER, wave, spring
SPACER, seal
SCREW, cap, hex hd
NUT, lock
BALL, joint, rod end
CABLE, steering push/pull, LL250
KNOB, pronged
BUSHING, nylon
SCREW, thd forming
KIT, repair, support, steering
(includes 89, 90)
BAR, handle, LL250
RETAINER, caplug
BEARING, cup/cone
SEAL, grease
BUSHING, strain relief
NUT, lock, nylon, thin pattern
3A3394E Repair - Parts
Qty.
Ref.
Part
Description
3
1
2
2
2
2
1
1
2
2
1
1
1
99
131
135
136
137
138
141
148
24M196
112798
119532
15E780
15K162
16N401
16M702
16M274
160
161
168
16X069
118444
24N496
169
178
184
205
206
207
211
212
214
114225
107439
127372
178342
C20004
114659
16X127
16X125
24U235
263
275
283
284
301
302
303
304
305
16N548
126215
16P554
16M007
24V564
24V565
24V566
16Y924
127543
HANDLE, control, forward/reverse
SCREW, thread forming, hex hd
BEARING, flanged
PIN, fork
BLOCK
SWITCH, push button
FRAME, upright, LL250, paint
CABLE, forward/reverse,
push/pull
COVER, display, LL250, painted
SCREW, mach, slot hex wash hd
KIT, repair, shield, paint
(includes 169)
TRIM, edge protection
SCREW, mach, hex hd
BUSHING, strain relief
CLIP, spring
SCREW, cap
GRIP, handle
LABEL, brand, LineLazer, dash
LABEL, brand, LineLazer, top
PLATE, control complete, see
page 8
GASKET, control
TRIM, edge, protection
PLATE, cover, control board
SCREW, drill, hex washer head
KIT, board, toggle switch
KIT, display, repair
KIT, switch, membrane
SPACER, toggle switch
SEAL, toggle switch
4
2
2
1
1
3
2
1
3
6
1
1
2
2
2
1
1
Qty.
1
1
2
1
1
1
1
1
1
6
1
1
6
1
1
1
2
1
1
1
1
1
1
2
1
1
1
3
3
53
Parts (24U235 Control Panel)
Parts (24U235 Control Panel)
4
10
5
159
157
11
2
9
156
3
158
153
1
7
152
6
8
10
154
ti23976a
54
3A3394E Repair - Parts
Parts (24U235 Control Panel)
Parts List
Ref. Part
1
2
3
4
5
6
7
8
9
10
Description
16X077 PLATE, control, LL250
24V561 KIT, repair, control board (includes
9)
16X074 LABEL
17C063 SWITCH, rocker, SPST
16M508 CABLE, choke
16M509 CONTROL, throttle
16N549 GASKET, throttle
109466 NUT, lock, hex
111839 SCREW, mach, pnh, sems
16X075 SWITCH, ignition
3A3394E Repair - Parts
Qty.
1
1
1
1
1
1
1
2
8
1
Ref. Part
Description
11
152
153
154
156
157
158
159
WIRE, positive
BUSHING, pressure control mount
NUT, panel
SHAFT, flexible
RING, retaining
KNOB, pressure control
SCREW, set, sch, 1/4-20
LABEL, control
1
1
1
1
1
1
1
1
24U235 PLATE, control (includes 1, 2, 3, 4,
5, 6, 7, 8, 9, 10, 11)
1
17C064
16Y411
119775
24V563
115999
16Y408
101962
15A464
Qty.
55
Parts
Parts
242
6
54
282
241
126
302
300
301
282
60
127
213
58
61
219
6
55
81
81
78
55
70
56
71
79
57
65
64
71
59
67
82
62
3
66
68
55
166
242
191
22
76
77
55 75
63
337
40
140
139 140
82
190
166
55
9
33
6
84
80
53
124
275
83
51
125
80
55
54a
6
5
85
33
1
ti19069b
56
3A3394E Repair - Parts
Parts
Parts List
Ref.
Part
Description
1
3
5
6
9
22
33
40
51
53
54
24L896
102393
108868
260212
111040
16M271
101566
125792
114982
16M072
24V562
54
25P364
54a
55
56
57
58
59
60
61
62
24N502
100023
16M075
125877
16M076
116596
125919
16M077
24N499
63
64
65
66
67
68
70
71
75
76
77
247930
16M078
125793
125876
117222
16M084
16U205
120087
100678
100521
110996
FRAME, painted, LL250
NUT, lock
CLAMP, wire
SCREW, hex washer hd, thd form
NUT, lock, insert, nylock, 5/16
HOSE, coupled, assembly, LL250
NUT, lock
BALL, joint, rod end
SCREW, cap, flng hd
FRAME, mount, engine, paint
KIT, repair, engine, GX390
(includes 54a, 60, 202, 241)
KIT, repair, engine, GX390
(includes 54a, 60, 202, 241)
(China only)
KIT, repair, rectifier, voltage
WASHER, flat
SPACER, clutch, 1.00 id x .5 thk
CLUTCH, electric, LL250
WASHER, 7/16 id x .25 thk
SCREW, cap, hex head
KEY, parallel, square, 1/4
PULLEY, double
KIT, repair, bracket, hydro pump
(includes 75, 76, 77, 242)
KIT, repair, hydraulic pump
PULLEY, 5 o.d. x 15mm
BELT, vee, tri-power, AX44
BELT, vee, tri-power, AX26
KEY, square
TRAY, hyd reservoir, LL250, paint
PULLEY, fan
SCREW, set, 1/4 in. x 1/2 in.
SCREW, cap hex hd
SCREW, cap hex hd
NUT, hex, flange head
3A3394E Repair - Parts
Qty.
1
1
1
8
2
2
3
1
4
1
1
1
1
11
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
2
Ref.
Part
Description
78
79
80
81
82
83
84
16M082
112406
120721
108481
100004
113677
16M715
85
124
125
126
107257
108851
119695
24N498
127
139
117284
15R309
140
158
166
190
191
202
111006
101962
16M276
124941
116829
126072
213
16X126
219
241
242
275
282
300
301
302
337
189892
194126
16M768
126215
16P547
260387
116876
116969
129636
BRACKET, clutch, anti-rotation
SCREW, cap, hex hd
SCREW, cap, 3/8-16, hexhd
SCREW, cap, hex hd
SCREW, cap, hex hd
BUSHING, nylon
BRACKET, mount, belt guard,
LL250
SCREW, thd forming
WASHER, plain
DAMPENER, engine mount
KIT, repair, guard, belt
(includes 6, 127, 242, 282, 300)
GRILL, fan guard
ROD, standoff, 1/4 in. od x
2.75 in. LG
SCREW, cap
SCREW, set, 1/4-20
HOSE, coupled, feed line, LL250
FITTING, long elbow, hydraulic
FITTING, 90 degree
KIT, Honda remote choke
(not shown)
LABEL, brand, LineLazer, DC,
side
LABEL, Graco logo
LABEL, warning
LABEL, pinch hazard iso
TRIM, edge, protection
PLATE, backer, belt guard, paint
SCREW, pan hd, x recess
WASHER, flat
NUT, lock
SPRING
Qty.
1
2
7
5
6
1
1
1
4
4
1
1
1
2
2
2
1
1
1
1
1
1
2
1
2
4
4
4
1
 Replacement warning labels may be ordered free of charge.
57
Parts
Parts
329
325
321
164
320
327
326
163
308
162
154
191
314
320
316
317
315
147
284
311
191
281
333
310
313
292 290
218
285
309
282
287
247
332
245
191
191
305
175
246
307
312
246 284
121
306
174*
174**
303
301
334
302
* LLV 250DC
**LLV 250SPS
ti28184a
58
72
3A3394E Repair - Parts
Parts
Parts List
Ref.
Part
52
72
121
128
144
147
154
111145
125794
181072
16X081
126108
124770
24V563
162
163
164
174
Description
KNOB, pronged
SCREW, taptite, hex washer hd
KIT, repair, strainer
BRACKET, dual tank retaining
SCREW, shoulder, socket head
FITTING, #8 jic tee, swivel
KIT, repair, shaft, flexible
(includes 162)
112303 SCREW, set, sch
15C958 GUARD, control, pressure
112166 SCREW, cap, sch
*278720
**278452
175 24V687
191 116829
217 15K440
218 16P142
245 114967
246 189674
247 127375
254 189285
281 15F149
282 194306
283 198119
284 101818
285 278722
287 16X071
290 248008
292 196180
301 15J513
RESERVOIR, 15 gallon
RESERVOIR, 25 gallon
KIT, pail, lid assembly
FITTING, 90 degree
LABEL, brand, GH/EH cooling
LABEL, hydraulic only icon
COUPLING, pipe, 1 in.
TUBE, intake
PLUG, 3”
LABEL, caution
TUBE, suction
HOSE, fluid
FITTING, elbow, barbed
CLAMP, hose
GASKET, pail
TUBE, drainline
HOSE, cpld, 1/4 in. x 44 in.
BUSHING
TANK, reservoir, blue
3A3394E Repair - Parts
Qty.
Ref.
Part
Description
2
2
2
2
2
1
1
302
303
305
306
307
308
309
310
311
312
313
314
315
316
317
320
101754
120604
24K967
116919
15E587
154594
16M160
107188
156401
16M112
119426
120726
198841
100084
116967
16X083
321
325
110792
17A581
326
327
17A582
246173
329
332
333
334
127686
117471
120184
116618
PLUG, pipe
GASKET, reservoir
TUBE, supply, hydraulic
FILTER
TUBE, suction
PACKING, o-ring
COVER, reservoir, LL250, painted
PACKING, o-ring
PACKING, o-ring
TUBE, suction, hydraulic, LL250
SCREW, mach, hex washer hd
CAP, breather, filler
RETAINER, ball, pressure bypass
BALL, metallic
SPRING, compression
KIT, repair, pump, 250SPS
(includes 310, 311, 332)
FITTING, elbow, male, 90 deg
KIT, repair, case drain
(includes 308)
TUBE, hydraulic case, drain
KIT, repair, oil filter (includes 315,
316, 317)
FITTING, tee
SCREW, mach, hex flat head
FITTING, hydraulic
MAGNET
2
1
1
2
1
2
4
1
1
2
2
2
1
2
2
2
4
2
2
2
2
1
Qty.
1
1
1
2
1
1
1
4
1
1
8
1
1
1
1
1
1
1
1
1
1
4
1
1
 Replacement warning labels may be ordered free of charge.
* LLV 250DC
** LLV 250SPS
59
Parts (Front Wheel)
Parts (Front Wheel)
Series A
55
32
243
31
47
43
46
44
15
45
43
42
41
258
185
40
34
142
257
29
3
39
55
37
30
1
36
36
Series B
243
35
ti19066b
55
31
47
46
45
43
43
44
258
30
143
137
257
41
42
55 142
29 185
138
1
135
136
40
136
34
3
37
39
36
35
ti27030a
60
3A3394E Repair - Parts
Parts (Front Wheel)
Parts List - Series A
Ref.
Part
1
3
15*
29
30
24L896
102393
15V264
113743
24L902
Description
FRAME, painted, LL250
NUT, lock
SPRING, extension
SCREW, cap, hex hd
ADJUSTER, caster, weldment,
LL250
31
126204 SCREW, cap, hex hd
34
24L897 CASTER, painted, LL250
35
16W284 WHEEL, foam filled (LL250 SPS,
DC)
36
193658 SPACER, seal
37
113471 SCREW, cap, hex hd
39
112405 NUT, lock
40
125792 BALL, joint, rod end
41*
125893 WASHER, thrust, 1-1/2 in. id
42*
16M267 LEVER, self centering, LL250
43
126112 BEARING, tappered 1 1/4, cone
44
125892 SEAL, bearing, 1-1/4 shaft
45
126064 SHIM, caster
46
125890 NUT, 1 1/4-12 unf
47
126063 CAP, dust
55
100023 WASHER, flat
142 100133 WASHER, lock, 3/8
185 290159 LABEL, reflective
243 101714 NUT, lock
257 16P143 LABEL, release hydraulic drive
258 16P144 LABEL, caster wheel adjustment
* Replace with upgrade Kit 24Y509
3A3394E Repair - Parts
Parts List - Series B
Qty.
1
2
1
2
1
1
1
1
2
1
1
2
2
2
2
1
2
1
1
4
2
2
1
1
1
Ref.
Part
1
3
29
30
24L896
102393
113743
24L902
Description
FRAME, painted, LL250
NUT, lock
SCREW, cap, hex hd
ADJUSTER, caster, weldment,
LL250
31
126204 SCREW, cap, hex hd
34
24L897 CASTER, painted, LL250
35
16W284 WHEEL, foam filled (LL250 SPS,
DC)
36
193658 SPACER, seal
37
113471 SCREW, cap, hex hd
39
112405 NUT, lock
40
125792 BALL, joint, rod end
41*
17H372 WASHER, thrust, 1-1/2 in. id
42*
17H377 BRACKET, steering, self centering
43
126112 BEARING, tappered 1 1/4, cone
44
125892 SEAL, bearing, 1-1/4 shaft
45
126064 SHIM, caster
46
125890 NUT, 1 1/4-12 unf
47
126063 CAP, dust
55
100023 WASHER, flat
135* 17H386 BRACKET
136* 260213 SCREW
137* 17H387 LEVER, upper
138* 17H388 LEVER, lower
143* 17H374 SPRING
142 100133 WASHER, lock, 3/8
185 290159 LABEL, reflective
243 101714 NUT, lock
257 16P143 LABEL, release hydraulic drive
258 16P144 LABEL, caster wheel adjustment
* Included in Kit 24Y509
Qty.
1
2
2
1
1
1
1
2
1
1
2
4
1
2
1
2
1
1
4
1
2
1
1
2
2
2
1
1
1
61
Parts (Gun Mount)
Parts (Gun Mount)
52
11
86
50
229
171
90
9
52
49
170
33
172
226
18
52
173
228
229
89
32
172
199
172j
310
172c
229a
172f
172b
172d
236
116
229b
229c
172n
172m
172g
172h
62
172k
172a
ti28185b
3A3394E Repair - Parts
Parts (Gun Mount)
Parts List
Ref.
Part
*9
*11
111040 NUT, lock, insert, nylock, 5/16
24N170 BRACKET, mount, pointer
complete
24N171 ARM, pointer, complete
17H445 INDICATOR, pointer
101566 NUT, lock
24N350 BRACKET, gun arm
16P136 LABEL, injection read manual iso
111145 KNOB, pronged
114653 SCREW, cap, flange hd
17H438 WASHER, spring, wave
17H441 COLLAR, screw, set
114966 KNOB, pronged
100527 WASHER, plain
102040 NUT, lock, hex
17J407 ARM, extension, bar, weldment
24Y645 KIT, clamp
24M638 BAR, gun holder, LLV 250SPS &
250DC
*18
*32
33
49
50
*52
*86
*87
*88
*89
*90
116
170
171
172
Description
Qty.
4
2
1
2
4
1
2
5
4
1
1
2
4
3
1
2
2
Ref.
Part
Description
172b
172c
172d
172f
172g
172h
172j
172k
172m
172n
173
199
226
227
228
229
236
*310
16M850
17J145
119647
15F750
15F209
24Y991
16N788
119664
15F214
24Y991
248157
16M671
245798
188135
17J408
17J424
126111
17H719
BRACKET, cable, gun,
ARM, holder, gun
SCREW, cap, socket, flthd
KNOB, holder, gun
STUD, pull, trigger
KIT, pivot
STUD, cable, gun, circlip
BEARING, sleeve
LEVER, actuator
KIT, pivot
KIT, accessory, gun, flex
CABLE, gun, solenoid
KIT, repair, hose
GUIDE, cable
ARM, extension, third gun
EXTENSION, vertical gun arm
RETAINER, circlip, external, 8mm
HOSE, pointer
Qty.
1
1
2
1
1
1
1
1
1
1
2
2
2
2
1
2
2
2
 Replacement warning labels may be ordered free of
172a 287569 KIT, repair, gun holder (includes
172f, 172k)
3A3394E Repair - Parts
1
charge.
* Included in Pointer Accessory Kit 24N162
63
Parts
Parts
255
16
10
12
17
259
146
15
14
13
6
5
4
26
2
27
22
21
19
20
2ref
25
28
64
ti19068b
3A3394E Repair - Parts
Parts
Parts List
Ref.
2
4
5
6
10
12
13
14
15
16
17
19
Part
125929
15K357
108868
260212
24M214
16M656
126073
24M215
15V264
16M743
112785
16M753
Description
Qty.
MOTOR, wheel
2
SENSOR, distance
1
CLAMP, wire
1
SCREW, hex washer hd, thd form
1
BRACKET, plate, pivot, brake, LL250 1
PIN, brake
4
RING, retaining, e ring, 1/2 dia
4
BRACKET, lock, brake, LL250
1
SPRING, extension
1
PEDAL, brake, LL250
1
SCREW, hex hd, flanged
1
FENDER, wheel, right, LL250, paint
1
3A3394E Repair - Parts
Ref.
20
21
22
25
26
27
28
146
255
259
Part
114766
801020
16M271
24N508
245340
125481
100104
16N394
16P141
16P139
Description
BOLT, cap hex head
NUT, lock, hex
HOSE, coupled, assembly, LL250
KIT, repair, hub and gear assy
KIT, repair, tire
NUT, wheel, 1/2-20
PIN, cotter
FENDER, wheel, left, LL250, paint
LABEL, parking brake icon
LABEL, multiple hazard iso
Qty.
8
8
2
2
2
8
2
1
1
1
 Replacement warning labels may be ordered free of charge.
65
Parts (Pump)
Parts (Pump)
366
119
367
368
369
347
370
118
366
371
346
364
363
356
354
353
380
379
378
346
345
344
343
377
393
115
117
102
372
370
307
94
114
95
376
94
95
122
226
387
384
385
386
389 388
66
116
113
391
390
95
392
123
103
104
106
105
112
120
107
95
123
ti19074b
3A3394E Repair - Parts
Parts (Pump)
Parts List (Pump)
Ref.
Part
Description
94*
95*
102
103
104
105
106
107
196179
196178
107210
287186
116551
197443
193394
277068
112
113
114
115
116
117
118
119
120
122
123
226
307*
343
344
345
346
347
119720
114528
15F911
100058
102040
15H108
15B804
15B063
24V064
191239
245797
245798
15G331
117739
112342
112561
117283
288754
353
354
356
108014
178226
178207
ELBOW, street
ADAPTER, nipple
SCREW
KIT, repair, magnet
RING, retaining
PIN, pump
NUT, retaining
KIT, repair, pump 200HS
(includes 95, 103, 104, 105)
SWITCH, reed w/connector
SCREW, mach, phillips, pnhd
GUARD, pump rod
SCREW, cap, hex hd
NUT, lock, hex
LABEL, pinch point
LABEL, Graco logo
LABEL
KIT, repair, suction hose
HOSE, coupled, 3/8 in. x 11 ft
KIT, repair, hose
HOSE, coupled, 1/4 in. x 7 ft
PLUG, pipe
WIPER, rod
NUT, jam
PACKING, block
PACKING, o-ring
KIT, repair, trip rod/piston (includes
118, 119)
PACKING, o-ring
SEAL, piston
BEARING, piston
Qty.
Ref.
Part
2
4
4
1
1
1
1
1
363
246176 SLEEVE, hydraulic, cylinder
(includes 346)
15A726 NUT, jam
117607 FITTING, elbow std thd
106276 SCREW, cap, hex head
155685 PACKING, o-ring
178179 WASHER, sealing
100139 PLUG, pipe
15F519 TUBE, hydraulic, supply
119841 FITTING, tee, branch
15H561 MANIFOLD
24V455 FILTER, 50 mesh, ultra
15C766 TUBE, diffusion
117285 PACKING, o-ring
287285 KIT, repair, filter cap
(includes 378, 379)
193710 SEAL, seat, valve
193709 SEAT, valve
245103 KIT, repair, drain valve
(includes 384, 385, 387, 388, 389)
114708 SPRING, compression
15G563 HANDLE, valve
116424 NUT, cap
111457 PACKING, o-ring
24N516 KIT, repair, transducer
(includes 390)
196181 FITTING, nipple
15A728 MANIFOLD, adapter
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
364
366
367
368
369
370
371
372
376*
377*
378*
379*
380*
384*
385*
386*
387*
388*
389*
390*
391*
392*
393
Description
Qty.
1
1
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
* Included in Filter Repair Kit 24N517
 Replacement warning labels may be ordered free of
charge.
3A3394E Repair - Parts
67
68
GUN 2
GUN 3
GUN 1
225
237
RED
224
221
187
**LLV 250DC only
* STANDING ON OPERATOR PLATFORM
238
BLACK
RED
PUMP (LEFT SIDE*)
PUMP (RIGHT SIDE*)
TO
GROUND
LUG
223
**112
4
112
189
**
PUMP (LEFT SIDE*)
319
PRESSURE
TRANSDUCER
134
CONTROL BOX
PUMP (RIGHT SIDE*)
150
91
BLACK
TO GROUND LUG
222
BLACK
RED
WHITE
BLACK
RED
92
RED
RED
215
CLUTCH SWITCH
BLACK
TO GROUND LUG
BLACK
(219)RED
BLACK
RED
214
CONTROL
BOARD
218
TRIGGER
SWITCH
217
CONTROL CABLE
TO ENGINE
GREY
STARTER SOLENOID
ENGINE GROUND
RED
BLACK
STARTER
SOLENOID
BLUE
WHITE
BLACK
BLACK
BLACK TO
GROUND
LUG
220
RED
216
KEY
SWITCH
54a
57
54
Wiring Diagram
Wiring Diagram
ti23961b
3A3394E Repair - Parts
Wiring Diagram
Wiring Parts List
Ref.
Part
Description
4
54
15K357 SENSOR, distance
24V562 KIT, repair, engine, GX390
(includes 54a)
54
25P364 KIT, repair, engine, GX390
(includes 54a) (China only)
54a 24N502 VOTLAGE REGULATOR
57
125877 CLUTCH, electric, LL250
91
16X079 CABLE, battery, positive
92
16X080 CABLE, battery, negative
112 119720 SWITCH, reed w/connector
134 24U234 CONTROL, box, handlebar
(includes 134a, 134b, 134c)
134a 24V565 KIT, display, repair
134b 24V564 KIT, board, toggle switch
134c 24V566 KIT, switch, membrane
150 115753 BATTERY, 33 AH, sealed
187 237686 WIRE, ground assembly w/ clamp
189 24U862 MANIFOLD, hydraulic, three piston
3A3394E Repair - Parts
Qty.
1
1
1
1
1
2
1
1
1
1
1
1
1
Ref.
Part
Description
189a 24N577 COIL, solenoid, hydraulic, manifold
(included in 189)
214b 24V561 KIT, repair, control board
215 17C063 SWITCH, rocker, SPST
216 16X075 SWITCH, ignition
217 24U233 CABLE, 18 conductor
218 16N401 SWITCH, pushbutton
219 17C064 WIRE, positive
220 16X078 HARNESS, wire, LL250DC
221 16N542 WIRE, positive battery
222 16N541 WIRE negative battery
223 16N540 HARNESS, light connection
224 16N539 HARNESS, sensor adapter
225 16N543 HARNESS, wire, hydraulic
actuator
237 126095 HOLDER, fuse
238 126096 FUSE, 30A
319 24N516 KIT, repair, transducer
Qty.
2
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
69
70
PUMP
(LEFT SIDE*)
366
74
109
108
370
372
371
366
111
196
98
366
73
197
198
304
198
109
108
370
372
371
366
194
193
189
2
22
LLV 250 DC only
* STANDING ON OPERATOR PLATFORM
PUMP
(RIGHT SIDE*)
111
74
147
191
166
63
22
333
110
190
166
327
2
350
320
309
166
Hydraulic Diagram
Hydraulic Diagram
ti23962b
3A3394E Repair - Parts
Hydraulic Diagram
Hydraulic Parts List
Ref. Part
2
22
63
73
74
98
108
109
110
111
147
166
189
Description
125929
16M271
247930
16X838
16X839
16P776
117328
117441
287175
287176
124770
16M276
24U862
MOTOR, wheel
HOSE, coupled, assembly, LL250
KIT, repair, hydraulic pump
HOSE, hydraulic, supply 2nd pump
HOSE, hydraulic, return 2nd pump
TUBE, supply, hydraulic
FITTING, nipple, straight
VALVE, ball
KIT, repair, hose, hydraulic supply
KIT, repair, hose, hydraulic return
FITTING, tee, 1/2 JIC, swivel
HOSE, coupled, feed line, LL250
MANIFOLD, hydraulic, three piston
(includes three 189a, 189b and
189c)
189a 24N577 COIL, solenoid, hydraulic, manifold
189b 24N490 KIT, repair, solenoid
(includes 189a)
189c 24V560 KIT, repair, actuator piston
3A3394E Repair - Parts
Ref. Part
Description
2
2
1
1
1
1
2
2
1
1
1
2
1
190
191
193
194
196
197
198
304
309
320
327
333
350
124941
116829
24M625
24M626
126082
126080
126081
155665
16M160
16X083
246173
120184
116829
1
1
366
370
371
372
117607
100139
15F519
119841
FITTING, long elbow, hydraulic
FITTING, 90 degree, w/adjustable
TUBE, supply, hydraulic
TUBE, supply, hydraulic
FITTING, tee, #8 x #8 x #6 JIC
FITTING, tee, street
FITTING, nipple, 3/8-18 x #6 JIC
UNION, adapter
COVER, reservoir, LL250, painted
KIT, repair, pump, 250SPS
KIT, repair, oil filter
FITTING, hydraulic
FITTING, 90 degree, w/adjustable
o-ring
FITTING, elbow std thd
PLUG, pipe
TUBE, hydraulic, supply
FITTING, tee, branch
Qty.
Qty.
1
1
1
1
1
2
2
1
1
1
1
1
2
4
2
2
2
1
71
Graco Standard 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. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco 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 parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER 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 property, or any other 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 Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
For patent information, see www.graco.com/patents.
TO PLACE AN ORDER, contact your Graco distributor or call 1-800-690-2894 to identify the nearest distributor.
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 3A3394
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2016, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision E, July 2019

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