Graco 334053A - LineLazer IV 25DC Self-Propelled Line Striper Repair Owner's Manual

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Graco 334053A - LineLazer IV 25DC Self-Propelled Line Striper Repair Owner's Manual | Manualzz

Repair

LineLazer IV 250

DC

Self-Propelled Line Striper

For the application of line striping materials.

For professional use only. For outdoor use only.

Not for use in hazardous locations or explosive atmospheres.

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 the engine manual.

Be familiar with the controls and the proper usage of the equipment.

Save these instructions.

Model Guns

24U242 2

24U243 2

24U810 3

24U820 3

Pressurized

Bead System

No

Yes

No

Yes

Description

LLIV 250DC

LLIV 250DC

LLIV 250DC

LLIV 250DC

Related Manuals:

333388

334054

311254

309277

312307

332230

Operation

Parts

Gun

Pump

Auto-Layout Applications Methods

Pressurized Bead System (PBS)

334053A

EN

2

Table of Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Component Identification (Striper) . . . . . . . . . . . . 6

Component Identification (Controls) . . . . . . . . . . . 7

Grounding Procedure

(For Flammable Materials Only) . . . . . . . . . . . 8

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 8

Ground Drive Belt Replacement . . . . . . . . . . . . . . 9

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Oil Reservoir Belt Replacement . . . . . . . . . . . . . . 10

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Hydraulic System Purging . . . . . . . . . . . . . . . . . . 11

Ground Drive Pump Replacement . . . . . . . . . . . . 13

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Oil Reservoir Pump Replacement . . . . . . . . . . . . 14

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Hydraulic Gun Manifold Replacement . . . . . . . . . 17

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Paint Pump Replacement . . . . . . . . . . . . . . . . . . . 20

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Hydraulic Motor Replacement . . . . . . . . . . . . . . . 21

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Clutch Replacement . . . . . . . . . . . . . . . . . . . . . . . 22

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . 25

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Touch-Pad Display . . . . . . . . . . . . . . . . . . . . . . . . . 27

Control Board Replacement . . . . . . . . . . . . . . . . . 28

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . 31

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 33

Forward/Reverse Cable Replacement . . . . . . . . . 34

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Steering Cable Replacement . . . . . . . . . . . . . . . . 36

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Front Wheel Replacement . . . . . . . . . . . . . . . . . . . 39

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Parking Brake Service . . . . . . . . . . . . . . . . . . . . . . 40

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Rear Wheel and Wheel Motors . . . . . . . . . . . . . . . 41

Rear Wheel Removal . . . . . . . . . . . . . . . . . . . . 41

Rear Wheel Installation . . . . . . . . . . . . . . . . . . . 41

Wheel Motor Removal . . . . . . . . . . . . . . . . . . . . 41

Wheel Motor Installation . . . . . . . . . . . . . . . . . . 42

Wheel Sensor Replacement . . . . . . . . . . . . . . . 42

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Wiring Parts List . . . . . . . . . . . . . . . . . . . . . . . . 49

Hydraulic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 50

Hydraulic Parts List . . . . . . . . . . . . . . . . . . . . . . 51

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 52

334053ARepair

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.

WARNING

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. 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).

• 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.

• Ground all equipment in the work area. See Grounding instructions.

• 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.

INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

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.

334053ARepair 3

4

Warnings

WARNING

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.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.

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.

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.

• 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.

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 MSDS 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.

• Do not carry passengers.

• Check work area for reduced overhead clearance (e.g. doorways, tree branches, parking ramp ceilings) and avoid contacting them.

334053ARepair

Warnings

WARNING

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 .

• Battery maintenance must only be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from battery.

• Do not dispose of battery in fire. The battery is capable of exploding.

• Follow local ordinances and/or regulations for disposal.

• Do not open or mutilate the battery. Released electrolyte has been known to be harmful to the skin and eyes and to be toxic.

• Remove watches, rings, or other metal objects.

• Only use tools with insulated handles. Do not lay tools or metal parts on top of battery.

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.

CALIFORNIA PROPOSITION 65

This product contains a chemical known to the State of California to cause cancer, birth defects or other reproductive harm. Wash hands after handling.

334053ARepair 5

Component Identification (Striper)

Component Identification (Striper)

6

1 Paint Filter, both sides

2 Adjustable Pad

3 Engine Fuel Cap

4 Wheel Motor Bypass Valve

5 Straight Line Adjuster

6 Gun Trigger Lock

7 Displacement Pump, both sides

8 Brake

9 Operator Platform

10 Serial Label under operator platform

11 Rear Gun Arm Mount, both sides

12 Hydraulic Fill Cap / Dipstick

13 Prime / Drain Valve, both sides

14 Handle Bar Height Adjustment Knob

15 Two Paint Hoppers (15 gallon / 56 liter)

16 Hydraulic Oil Filter

17 Front Gun Mount, both sides

18 Steering Handle

334053ARepair

Component Identification (Controls)

1 2

1

2

11

Component Identification (Controls)

3 3

4

5

10

9

8 ti23143a

1 Gun Trigger Control

2 Gun 1, 2, 3 Selector

3 Display

4 Forward / Reverse Lever

5 Pressure Control

6 Hydraulic Pump Valve, both sides

7

6 on off

7 12V Accessory Jack

8 Engine Key Switch, Off - On - Start

9 Engine Clutch Switch

10 Engine Choke

11 Engine Throttle

334053ARepair 7

8

Grounding Procedure (For Flammable Materials Only)

Grounding Procedure

(For Flammable Materials Only)

Pressure Relief Procedure

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.

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).

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 spraying and before cleaning, checking, or servicing the equipment.

1.

Perform Grounding Procedure if using flammable materials.

2.

Set both (2) pump valves to OFF . Turn engine OFF .

ti23146a ti2 3 144 a

3.

Turn pressure control to lowest setting. Trigger all guns to relieve pressure.

ti 33 05 a ti3441a PAINT

4.

Engage all gun trigger locks. Turn both (2) prime valves down. ti6473a ti 33 24 a

334053ARepair

Ground Drive Belt

Replacement

Removal

Installation

1.

Install belt onto pulleys.

Ground Drive Belt Replacement

1.

If equipped with a Pressurized Bead System, remove pressurized bead tanks and compressor, see Pressurized Bead System manual 332230.

2.

Loosen four screws and remove belt cover. ti19134a

2.

Tighten tensioning bolt to move two pulleys apart and tighten belt to proper tension (see table).

ti19128a

3.

Loosen two hold-down bolts.

ti19130a

4.

Loosen tension bolt to bring two pulleys closer together to create slack in the belt. ti19132a

Ground Drive Belt Tension Recommendations

Tension

New Belt

Frequency

Tension

Used Belt

Frequency

Gates Sonic Tension Meter

Settings: M = MASS = 85 g/m

W = # of belts = 1

S = Span = 157 mm

53 +/- 2 Lbf (236 +/- 9 N)

167 +/- 3 Hz

45 +/- 2 Lbf (200 +/- 9 N)

155 +/- 3 Hz

3.

Install mounting plate and tighten two hold-down bolts.

ti19129a

4.

Replace belt cover and tighten four screws. ti19131a

5.

Remove belt.

334053ARepair ti19133a ti19128a

5.

If equipped with a Pressurized Bead System, install pressurized bead tanks and compressor, see Pressurized Bead System manual 332230.

9

Oil Reservoir Belt Replacement

Oil Reservoir Belt

Replacement

Installation

1.

Replace belt.

Removal

NOTE: Ground drive belt must be removed before oil

reservoir belt can be replaced, see Ground Drive Belt

Replacement , page 9.

1.

Loosen four hold-down bolts.

ti19149a

2.

Tighten two adjustment bolts evenly and maintain belt alignment. Tighten belt to proper tension (see table).

ti19147a

2.

Loosen two adjustment bolts to bring pulleys closer together to create slack in the belt.

3.

Remove belt. ti19146a ti19150a

Oil Reservoir Belt

Tension Recommendations

Tension

New Belt

Frequency

Tension

Used Belt

Frequency

Gates Sonic Tension Meter

Settings: M = MASS = 85 g/m

W = # of belts = 1

S = Span = 236 mm

55 +/- 2 Lbf (245 +/- 9 N)

114 +/- 2 Hz

48 +/- 2 Lbf (214 +/- 9 N)

106 +/- 2 Hz

3.

Tighten four hold-down bolts. ti19148a ti19151a

4.

Install Ground Drive Belt and tighten to proper

tension, see Ground Drive Belt Replacement , page 9.

10 334053ARepair

Hydraulic System Purging

Hydraulic System Purging

4.

Start engine and run at low speed.

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 spraying and before cleaning, checking, or servicing the equipment.

Follow this procedure after replacing any hydraulic component other than the hydraulic gun manifold which is self-purging.

1.

Set LineStriper on blocks so wheels are off ground.

ti23889a

5.

Turn on the Main Power Switch to engage clutch.

2.

Fill oil reservoir to “Full” range.

ti18587a

Full Range (cold)

ti343 1 a

3.

Make sure drive wheel release is closed (+).

+ ti23890a

6.

Slowly pull forward/reverse control lever in forward and reverse directions 10 times.

ti18576a ti23891a

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.

334053ARepair 11

Hydraulic System Purging

7.

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.

8.

Repeat step 7 for the other pump.

9.

The hydraulic gun manifold is self-purging.

10. Use the key switch to turn engine off. Check oil level. Top off to “Full” range.

ti23892a ti343 1 a

Full Range (cold)

12 334053ARepair

Ground Drive Pump Replacement

Ground Drive 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 spraying and before cleaning, checking, or servicing the equipment.

Removal

1.

Remove ground drive belt, see

Ground Drive Belt

Replacement , page 9.

2.

Use allen wrench to remove two set screws (71) from pulley (64).

3.

Slide pulley (64) off shaft and save key (60).

4.

Disconnect all fittings and hoses from pump (63).

NOTE: Oil will spill out of hoses. Have rags and waste pail nearby.

5.

Remove nut (3) and disconnect tie rod (40) underneath pump (63).

6.

Remove two mounting bolts (82) and washers (55) to remove pump (63) from bracket.

Installation

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).

3.

Connect all fittings and hoses to pump (63).

4.

Install key (60) onto pump shaft and slide pulley (64) onto shaft.

5.

Align pulley to outer clutch groove and tighten two set screws (71).

6.

Install ground drive belt and tighten to proper tension, see

Ground Drive Belt Replacement , page 9.

7.

Purge Hydraulic System see, Hydraulic System

Purging , page 11.

71

60

63

71

64

62

3

55 ti19135a

82

40

334053ARepair 13

Oil Reservoir Pump Replacement

Oil Reservoir Pump

Replacement

4.

Loosen two set screws and cable.

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 spraying and before cleaning, checking, or servicing the equipment.

Removal

1.

Remove belt cover, see

Oil Reservoir Belt

Replacement , page 10.

2.

Remove oil filter and disconnect five hydraulic hoses from oil reservoir.

ti19142a

5.

Remove eight screws and oil reservoir cover with pump.

ti23901a

3.

Loosen nut and slide cable sleeve down to gain access to the two cable set screws.

ti23902a

6.

Remove pulley from pump. Remove four screws and pump from reservoir cover.

ti19672a ti19144a

14 334053ARepair

Installation

1.

Install pump onto oil reservoir cover with four screws. Make sure the five o-rings are in place.

Oil Reservoir Pump Replacement

3.

Install pulley on pump shaft and maintain belt alignment to inner groove of the clutch pulley. Tighten two pulley screws.

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.

ti19670a

4.

Turn pressure control knob clockwise until seated.

ti23905a

5.

Turn hydraulic pump pressure control clockwise until seated then counterclockwise 1/6 turn.

ti23904a

334053ARepair ti23906a

15

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.

7.

Slide cable sleeve up and tighten screw. ti19143b ti19145a ti23901a

9.

Install and tension belts, see

Oil Reservoir Belt

Replacement

, page 10 and Ground Drive Belt

Replacement , page 9.

10. Fill reservoir and purge hydraulic system, see

Hydraulic System Purging , page 11.

16 334053ARepair

Hydraulic Gun Manifold

Replacement

Removal

1.

Remove tank lids and siphon tubes.

Hydraulic Gun Manifold Replacement

4.

Remove four screws and pad.

ti19164a

5.

Label wire harnesses GUN 1, GUN 2, and GUN 3 .

Disconnect three wire harnesses from solenoids.

Gun 3

Gun 2

Gun 1

2.

Remove tanks 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.

ti19163a

Gun # ti19159a

334053ARepair 17

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

18 334053ARepair

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

5.

Connect gun cables to actuators.

ti23964a ti23916a

7.

Install pad and tighten four screws.

8.

Install front shield to unit and tighten six screws.

9.

Install tanks, lids and insert siphon tube into tanks.

NOTE: The hydraulic gun manifold is self-purging. ti19159a

334053ARepair 19

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 spraying and before cleaning, checking, or servicing the equipment.

Removal

1.

Perform Pressure Relief Procedure , page 8.

2.

Disconnect suction tube (120).

3.

Disconnect hose (123) and fitting (95) from paint pump (107). Note orientation of fitting (95) for installation.

4.

Remove screw (115), nut (116) and pump guard

(114).

5.

Use hammer to loosen pump jam nut (106).

6.

Slide down retainer (104) and remove pin (105).

7.

Unscrew and remove paint pump (107).

Installation

1.

Extend pump rod out of pump (107).

2.

Insert pump rod into hydraulic motor rod and install pin (105) and retainer (104).

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).

5.

Install guard (114) with screw (115) and nut (116).

6.

Install fitting (95) and connect hose (123).

7.

Connect suction tube (120).

115

114

95

123

116

20

120 ti19138b

334053ARepair

104

106

105

107

Hydraulic Motor Replacement

Hydraulic Motor

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 spraying and before cleaning, checking, or servicing the equipment.

Removal

1.

Perform

Pressure Relief Procedure , page 8.

2.

Remove paint pump, see Paint Pump Replacement , page 20.

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

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.

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).

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 20.

6.

Purge hydraulic system, see Hydraulic System

Purging , page 11.

74 98

108

112 113

109

116 ti23917a

334053ARepair 21

Clutch Replacement

Clutch Replacement

6.

Remove three bolts (81) and pulley (61).

61

Removal

1.

Remove ground drive belt, page

Ground Drive Belt

Replacement , page 9.

2.

Remove oil reservoir belt, see

Oil Reservoir Belt

Replacement , page 10.

3.

Remove two hold-down bolts for the ground drive pump bracket.

81 ti19216a

7.

Remove engine recoil starter and place a screwdriver through the recoil starter cup. ti19696a ti19215a

4.

Unscrew tensioning bolt from the ground drive pump bracket. ti19131a

5.

Move ground drive pump assembly aside.

ti19213a ti19697a

8.

Remove center bolt (59) and remove clutch (57).

56

57

59

58

60 ti19214a

22 334053ARepair

Clutch Replacement

9.

Disconnect clutch connector to main wire harness.

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.

58

59 ti19212a

Installation

1.

Install spacer (56) and key (60) onto crankshaft.

Slide clutch (57) onto crankshaft.

56

57 ti19692a

4.

Install pulley (61) and torque three screws (81) to 10 ft-lb (13 N•m).

61

81

59

58

60 ti19214a ti19216a

5.

Install recoil starter onto engine.

2.

Align clutch and wire in bracket. ti19211a

334053ARepair ti23918a

23

Clutch Replacement

6.

Connect clutch to wire harness. 7.

Install ground drive pump assembly with tensioning and two hold-down bolts.

ti19212a ti19908a

8.

Install and tension belts, see

Oil Reservoir Belt

Replacement

, page 10 and Ground Drive Belt

Replacement , page 9.

24 334053ARepair

5.

Disconnect throttle cable.

Engine Replacement

Engine Replacement

Removal

1.

Remove clutch, see

Clutch Replacement , page 22.

NOTICE

NOTICE

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.

6.

Disconnect choke cable. ti19185a

7.

Remove four mounting bolts from engine.

ti19183a

Engine Ground

Ignition

Voltage Regulator

Starter Solenoid

Battery

4.

Remove air filter cover, element and base. ti23921 ti19187a

8.

Remove engine. NOTE: Engine voltage regulator is located below engine mounting plate. Remove two screws and disconnect wires.

334053ARepair ti19186a ti19703a

25

Engine Replacement

Installation

1.

Install engine voltage regulator below engine mounting plate with two screws. Connect regulator to wire harness.

4.

Install throttle cable.

a.

Place speed lever to high speed.

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. d.

Tighten screw on hex-shaped pivot.

e.

Verify proper operation of engine choke.

ti19186a

6.

Connect seven wires to engine.

ti19686a

Engine Ground

Ignition

Voltage Regulator

Starter Solenoid

Battery ti23921

7.

Install clutch, see Clutch Replacement , page 22.

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.

26 334053ARepair

Touch-Pad Display

Touch-Pad Display

1

3

2

1

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)

3 ti23924a

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)

334053ARepair 27

Control Board Replacement

Control Board Replacement

Removal

1.

To disconnect power remove fuse, see

Fuse

Replacement , page 33.

2.

Remove siphon tubes and lids.

5.

Remove four screws and remove pad.

3.

Remove tanks from unit.

4.

Remove six screws and then remove front shield from unit.

6.

Remove six screws and control shroud. ti23930a ti19163a ti23931a

28 334053ARepair

Control Board Replacement

7.

Remove two screws and splash shield. ti24973a

8.

Disconnect all wires from control board.

9.

Remove eight control board mounting screws and then remove control board.

3.

Connect all wires to control board. See,

Wiring Diagram , page 48. Pump number 1 is on the left when

you stand in the operator position.

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 33.

Check control, switches and display.

7.

Install splash shield with two screws.

ti24074a

Installation

1.

Install control board with eight mounting screws.

8.

Install control shroud with six screws. See Removal

step 6.

9.

Install pad and tighten four screws. ti2376a ti24075a

2.

Before connecting wires to control board, make sure that all wires are routed above the two steering cables.

334053ARepair ti23930a

29

Control Board Replacement

10. Install front shield and tighten six screws. 11. Install tanks, lids and siphon tubes. ti19200a

12. If control board was replaced select language, units, and calibrate distance sensor (see Operation manual).

30 334053ARepair

Battery Replacement

Battery Replacement

5.

Lift battery and slide it back onto the platform. Disconnect two red wires from battery.

Removal

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.

ti24077a

6.

Remove battery.

NOTICE

To reduce the risk of battery damage and shorts, always disconnect NEGATIVE (black wire) first.

4.

Disconnect two black wires from battery.

Installation

NOTICE

To reduce the risk of battery damage and shorts, always connect NEGATIVE (black wire) last.

1.

Place battery on operator platform. Connect two red wires to positive (+) post of the battery.

ti24079a ti24078a

334053ARepair 31

Battery Replacement

2.

Pickup and slide battery into mounting position.

Install battery hold down strap.

3.

Connect two black wires to negative (–) post of the battery.

4.

Place coiled paint hoses over bracket and secure with straps.

ti24104a

32 334053ARepair

Fuse Replacement

1.

Remove fuse cover.

2.

Use needle-nose pliers to remove old fuse and inspect it for an open circuit.

Fuse Replacement

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.

4.

Use needle-nose pliers to install new fuse.

5.

Replace cover.

ti23941a

334053ARepair 33

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

148

3

3.

Remove tanks from unit.

4.

Remove six screws and front shield from unit.

ti23942a

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).

ti19163a

5.

Loosen four screws and remove belt cover.

34

62

3

148

40 ti19700a

8.

Install new cable (148) as old cable is removed to follow same route through frame.

334053ARepair

Forward/Reverse Cable Replacement

Installation

1.

Install new cable (148) by following same route as old cable is being removed.

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).

62

4.

Verify that the handlebar forward/reverse lever does not touch handlebar grips. Adjust cable and ball joints if needed.

5.

Install belt cover and tighten four screws.

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.

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

148

3 ti23942a

334053ARepair 35

Steering Cable Replacement

Steering Cable Replacement

2.

Remove six screws and control shroud.

Removal

1.

Loosen four screws and remove pad.

ti23930a ti23931a

36 334053ARepair

3.

Apply parking brake. Raise front wheel off the ground and support frame on two jack stands.

Steering Cable Replacement

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 ti23943a ti23944a

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.

48

3

40 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.

334053ARepair 37

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

3

40 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.

Adjust to match other side of handlebar ti19685a ti23944a

6.

Verify that handlebar is aligned straight with frame.

If misaligned, adjust nuts on cable (48) to straighten handlebar to frame.

7.

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).

8.

Install pad and tighten four screws.

9.

Remove jack stands and test drive sprayer to check steering. Adjust if needed. Install cable ties in loca-

tions noted in step 6 of Removal.

10. Verify straight line tracking and adjust if necessary

(see Operation manual).

11. Install control shroud and tighten six screws.

38 334053ARepair

Front Wheel Replacement

Front Wheel Replacement

Removal

1.

Apply parking brake. Raise front wheel off ground and support frame on two jack stands.

Installation

1.

Insert two spacers (36) into wheel (35) and slide into fork (34).

34

39

37 36

2.

Remove locknut (39) from axle bolt (37) and remove axle bolt (37) from fork (34).

34 ti19693a

39 ti20125a

36

35

2.

Insert axle bolt (37) through fork (34), spacers (36) and wheel (35).

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).

334053ARepair 39

Parking Brake Service

Parking Brake Service

16

Removal

1.

Remove tire, wheel hub, and fender. See,

Wheel

Motor Removal , page 41.

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.

A

10

14

17

A

15

B

Installation

1.

Install lever (14) with pin (B) and clip (13).

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 41.

5.

Adjust screw (17) to hold tire when brake lever (16) is depressed.

40 334053ARepair

Rear Wheel and Wheel Motors

Rear Wheel and Wheel Motors

Wheel Motor Removal

1.

Place jack under frame near wheel and raise jack.

2.

Remove four lug nuts (22) and wheel (16).

Rear Wheel Removal

1.

Set LineStriper on blocks so wheels are off ground.

16 ti18587a

2.

Remove four lug nuts (22) and wheel (16).

16

22 ti18589a

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.

22 ti18589a

3.

Remove pin (56), castle nut (21b) and wheel hub

(22b). Wheel hub may require a wheel puller; not supplied by Graco.

112

6

5

79

4

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).

6.

Disconnect two hydraulic hoses (112) from wheel motor (21a) and remove wheel motor.

ti18588a

3.

Inflate rear tires to 55 +/- 5 psi (380 +/- 34 kPa).

334053ARepair 41

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).

112

6

5

79

4

21a

78

22b

19

4.

Install wheel hub (22b), castle nut (21b), and pin

(56).

21b

56 ti23945a

5.

Install wheel (16) and four lug nuts (22). Alternately tighten lug nuts opposite each other.

16 ti23930a

2.

Place jack under frame on the side opposite of the brake and raise jack.

3.

Remove four lug nuts (22) and wheel (16).

16

22

22 ti18589a

4.

Disconnect wheel sensor connector from wire harness. ti18589a

6.

Purge hydraulic system. See Hydraulic System

Purging

, page 11.

Wheel Sensor Replacement

Removal

1.

Loosen four screws and remove pad.

ti19328b

42 334053ARepair

Rear Wheel and Wheel Motors

5.

Use wrench to remove screw (6), clamp (5), and wheel sensor (4).

6

5 ti18564a ti19329a

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

Installation

1.

Install wheel sensor (4) and clamp (5) with screw

(6). See Removal

step 5.

2.

Connect wheel sensor connector to wire harness.

22 ti18589a

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

4.

Press gun trigger control button and rotate hub by hand exactly three turns.

8.

Calibrate sprayer. See Operation manual. ti23930a

334053ARepair 43

Troubleshooting

Troubleshooting

General

Problem

Engine will not crank

Engine cranks slow

Engine will not start

High engine speed at no load

Machine will not drive

Cause Solution

Battery is discharged.

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.

Engine oil level is low.

Turn key switch to ON. Choke engine and pull recoil starter rope.

Replace key switch.

Replace wire harness, see

Wiring Diagram

Turn engine clutch switch OFF.

, page 48.

Refill gas tank. See engine manual.

Move fuel shut-off lever to ON position.

Check oil level and add oil if necessary. See engine 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.

Worn engine governor.

Reset high speed to 3600 - 3700 engine rpm at no load.

Adjust or replace engine governor.

Engine clutch switch is OFF.

Hydrostatic drive bypass valve is open.

Hydraulic fluid is low.

Drive cable is disconnected or broken.

Turn engine clutch switch ON.

Close wheel motor bypass valve to engage drive. See

Operation manual

Shut off striper and add fluid*.

Clutch wire harness is disconnected or broken.

Clutch does not work.

Ground drive belt is worn or broken.

Ground Drive Pump is worn or not working.

Wheel motor(s) worn or not working.

Reconnect or replace cable.

Reconnect or replace harness as necessary.

Replace clutch.

Adjust or replace ground drive belt.

Replace ground drive pump.

Replace wheel motor.

44 334053ARepair

Troubleshooting

Engine operates, but displacement pump does not operate

Problem

Displacement pump operates, but output is low on upstroke

Displacement pump operates but output is low on downstroke and/or on both sides

Pump is difficult to prime

Cause Solution

Engine clutch switch is OFF.

Pump ball valve is OFF.

Pressure setting is too low.

Turn engine clutch switch ON.

Turn pump ball valve ON.

Turn pressure adjusting knob clockwise to increase pressure. See Operation manual.

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.

Open prime/drain valve.

Shut off sprayer. Add fluid*.

Replace oil reservoir belt, see

Oil Reservoir Belt

Replacement , page 10.

Reverse tip to clean. See Operation manual.

Repair pump. See Pump manual.

Hydraulic motor not shifting.

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.

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 seating properly.

Pump packings are worn or damaged.

Clean intake valve. See Pump manual.

Large pressure drop in hose with heavy materials.

Engine speed is too high.

Replace pump packings. See Pump manual.

Use larger diameter hose and/or reduce overall length of hose. Use of more than 100 ft x 1/4 in. hose significantly 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.

Suction tube strainer is clogged.

Suction tube air leak.

Bring sprayer to Graco distributor for repair.

Clean strainer

Tighten suction tube

Drain line to paint hopper is clogged.

Intake valve is leaking.

Clean drain line

Clean intake valve. Be sure ball seat is not nicked or worn and that ball seats well. Reassemble valve.

Pump packings are worn.

Paint is too thick.

Replace pump packings. See Pump manual.

Thin the paint according to supplier recommendations.

Decrease throttle setting before priming pump. See

Operation manual.

334053ARepair 45

Troubleshooting display packing nut

Problem

Low stall or run pressure shown on

Excessive paint leakage into throat

Fluid is spitting from gun

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

Cause

Pressure setting too low.

New pump or new packings.

Faulty transducer.

Throat packing nut is loose.

Throat packings are worn or damaged.

Displacement rod is worn or damaged.

Air in pump or hose.

Tip is partially clogged.

Fluid supply is low or empty.

Piston rod seal worn or damaged.

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.

Missing or damaged magnet, both pumps.

Distance not adding properly

(MEASURE mode will be inaccurate and speed will be wrong)

Mils not calculating or calculates wrong

Bad sensor, both pumps.

Machine not calibrated.

Rear tire pressure is too low or too high.

Gear teeth missing or damaged

(right side when standing on platform).

Distance sensor is loose or broken.

Distance sensor.

Gallon counter.

Line width not entered.

Bad or damaged display board.

Solution

Turn pressure adjusting knob clockwise to increase pressure. See Operation manual.

Pump break-in period takes up to 100 gallons of material.

Replace transducer.

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.

Replace hydraulic motor piston rod wiper and seal.

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 33.

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 21.

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 41.

Reconnect or replace sensor. See

Wheel Sensor

Replacement , page 42.

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.

46 334053ARepair

Troubleshooting

Problem Cause Solution

Pressure control knob does not rotate Knob is jammed.

Pressure control knob rotates freely with no pressure change

Gun does not trigger

Set screw at hydraulic pump connection is loose.

Remote cable is broken or disconnected.

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).

System pressure is too low.

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 14 step 3.

Replace or reconnect cable. See Oil Reservoir Pump

Replacement , page 14 step 3.

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.

Gun triggering is slow

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.

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 47.

Reload the correct pattern.

Perform calibration routine (see Operation manual).

PARKING LAYOUT Mode

Gun selector switch is OFF Turn gun selector switch ON.

Gun does not apply dots Dot size setting is too small

Pressure is too low

Increase dot size.

Increase pressure to 1000 psi.

*

Use only Graco approved hydraulic fluid 169236 (5 gallons / 18.9 liter) or 207428 (1 gallon / 3.8 liter)

334053ARepair 47

Wiring Diagram

Wiring Diagram

48 ti23961a

334053ARepair

Wiring Diagram

Wiring Parts List

Ref.

Part Description Qty.

4 15K357 SENSOR, distance

54 24U562 KIT, repair, engine, GX390

(includes 54a)

54a 24N502 VOTLAGE REGULATOR

57

91

125877 CLUTCH, electric, LL250

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 1

189a 24N577 COIL, solenoid, hydraulic, manifold

(included in 189)

2

1

1

1

1

1

1

1

1

1

2

1

Ref.

Part Description

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.

1

1

1

1

3

1

1

1

1

1

1

1

1

1

1

334053ARepair 49

Hydraulic Diagram

Hydraulic Diagram

50 ti23962a

334053ARepair

Hydraulic Diagram

Hydraulic Parts List

Ref. Part Description Qty.

2 125929 MOTOR, wheel

22 16M271 HOSE, coupled, assembly, LL250

63 247930 KIT, repair, hydraulic pump

73 16X838 HOSE, hydraulic, supply 2nd pump 1

74 16X839 HOSE, hydraulic, return 2nd pump 1

98 16P776 TUBE, supply, hydraulic

108 117328 FITTING, nipple, straight

1

2

2

2

1

109 117441 VALVE, ball

110 287175 KIT, repair, hose, hydraulic supply

111 287176 KIT, repair, hose, hydraulic return

147 124770 FITTING, tee, 1/2 JIC, swivel

166 16M276 HOSE, coupled, feed line, LL250

189 24U862 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 1

1

1

1

1

2

1

2

1

Ref. Part Description

190 124941 FITTING, long elbow, hydraulic

191 116829 FITTING, 90 degree, w/adjustable

193 24M625 TUBE, supply, hydraulic

194 24M626 TUBE, supply, hydraulic

196 126082 FITTING, tee, #8 x #8 x #6 JIC

197 126080 FITTING, tee, street

198 126081 FITTING, nipple, 3/8-18 x #6 JIC

304 155665 UNION, adapter

309 16M160 COVER, reservoir, LL250, painted

320 16X083 KIT, repair, pump, 250SPS

327 246173 KIT, repair, oil filter

333 120184 FITTING, hydraulic

350 116829 FITTING, 90 degree, w/adjustable o-ring

366 117607 FITTING, elbow std thd

370 100139 PLUG, pipe

371 15F519 TUBE, hydraulic, supply

372 119841 FITTING, tee, branch

Qty.

1

1

1

1

1

2

2

2

1

1

1

1

1

2

2

4

2

334053ARepair 51

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 334053

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revision A - July 2014

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