Graco 3A3394B, LineLazer V 250SPS and 250DC Self-Propelled Line Striper, Repair/Parts Owner's Manual

Add to my manuals
72 Pages

advertisement

Graco 3A3394B, LineLazer V 250SPS and 250DC Self-Propelled Line Striper, Repair/Parts Owner's Manual | Manualzz

Repair - Parts

LineLazer V 250

SPS

and 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 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

17H471 2

17H472 3

17H473 2

17H474 3

Pressurized

Bead System

No

No

Yes - 2 Tank

Yes - 2 Tank

Description

LLV 250 DC

LLV 250 DC

LLV 250 DC

LLV 250 DC

17H466 1

17H467 2

17H468 1

17J951 2

17H469 2

No

No

Yes - 1 Tank

Yes - 1 Tank

Yes - 2 Tank

LLV 250

LLV 250

SPS

LLV 250 SPS

LLV 250 SPS

LLV 250 SPS

SPS

Related Manuals:

3A3393

311254

309277

3A3428

332230

Operation

Gun

Pump

Auto-Layout Applications Methods

Pressurized Bead System (PBS)

Use only genuine Graco replacement parts.

The use of non-Graco replacement parts may void warranty.

3A3394B

EN

Table of Contents

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

Important Laser Information for Units with Laser

Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Battery Disposal . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

2

Forward/Reverse Cable Replacement . . . . . . . . . 35

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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

3A3394BRepair - 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.

3A3394BRepair - 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 3A3394BRepair - 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.

3A3394BRepair - Parts 5

6

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.

3A3394BRepair - 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

.

ti25930a

3A3394BRepair - Parts 7

Component Identification (LLV 250DC Shown)

Component Identification (LLV 250

DC

Shown)

8

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

*LLV 250SPS has only 1 paint hopper and 1 pump.

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

3A3394BRepair - Parts

Component Identification (Controls)

Component Identification (Controls)

1 2

1

2

3 3

11

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

3A3394BRepair - Parts 9

Grounding Procedure (For Flammable Materials Only)

Grounding Procedure

(For Flammable Materials Only)

2.

Set pump valve(s) to OFF (250 SPS has one pump valve; 250 DC has two pump valves). Turn engine OFF .

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).

ti2 3 144 a

3.

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

ti23146a

Pressure Relief Procedure

ti 33 05 a ti3441a PAINT

4.

Engage all gun trigger locks. Turn prime valve(s) down

(250 SPS has one prime valve; 250 DC has two prime valves). ti6473a

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.

1.

Perform Grounding Procedure if using flammable materials. ti 33 24 a

5.

If you suspect the spray tip or hose is clogged or that pressure has not been fully relieved: a.

VERY SLOWLY loosen the tip guard retaining nut or the hose end coupling to relieve pressure gradually.

b.

Loosen the nut or coupling completely.

c.

Clear the obstruction in the hose or tip.

10 3A3394BRepair - Parts

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

New Belt

Used Belt

Tension

Frequency

Tension

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. ti19133a ti19128a

5.

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

3A3394BRepair - Parts 11

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 11.

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.

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

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

114 +/- 2 Hz

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

106 +/- 2 Hz

S = Span = 236 mm

3.

Tighten four hold-down bolts.

3.

Remove belt. ti19148a ti19151a

4.

Install Ground Drive Belt and tighten to proper tension, see

Ground Drive Belt Replacement , page 11.

12 3A3394BRepair - Parts

5.

Start engine and run at low speed.

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.

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.

ti23889a

6.

Turn on the Main Power Switch to engage clutch.

3.

Fill oil reservoir to “Full” range.

ti18587a ti23890a

7.

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

Full Range (cold)

ti343 1 a

4.

Make sure drive wheel release is closed (+).

+ ti18576a

3A3394BRepair - Parts 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.

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.

ti23892a ti343 1 a

Full Range (cold)

14 3A3394BRepair - Parts

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

Removal

1.

Perform

Pressure Relief Procedure , page 10.

2.

Remove ground drive belt, see

Ground Drive Belt

Replacement , page 11.

3.

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

4.

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

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.

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 11.

71

60

63

71

64

62

3

55 ti19135a

82

40

3A3394BRepair - Parts 15

Oil Reservoir Pump Replacement

Oil Reservoir Pump

Replacement

5.

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 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.

ti19142a

6.

Remove eight screws and oil reservoir cover with pump.

ti23901a

4.

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

ti19144a

16 ti23902a

7.

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

ti19672a

3A3394BRepair - Parts

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

3A3394BRepair - Parts ti23906a

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.

7.

Slide cable sleeve up and tighten screw. ti19143b 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 3A3394BRepair - Parts

Hydraulic Gun Manifold Replacement

Hydraulic Gun Manifold

Replacement

Removal

1.

Remove tank lid(s) and siphon tube(s). ti19164a

5.

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

Disconnect three wire harnesses from solenoids.

Gun 3

Gun 2

Gun 1

LL250 DC 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.

ti19163a

Gun # ti19159a

4.

Remove four screws and pad.

3A3394BRepair - 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 3A3394BRepair - 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

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 tank(s), lid(s) and insert siphon tube(s) into tank(s).

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

3A3394BRepair - 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.

Removal

1.

Perform

Pressure Relief Procedure , page 10.

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

22

120 ti19138b

3A3394BRepair - Parts

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

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

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 22.

6.

Purge hydraulic system, see

Hydraulic System

Purging , page 13.

74 98

112 113

108

109

116 ti23917a

3A3394BRepair - 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.

3.

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

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

24 3A3394BRepair - Parts

Clutch Replacement

9.

Disconnect clutch connector to main wire harness.

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

5.

Install recoil starter onto engine.

ti19216a 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.

3A3394BRepair - Parts 25

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 12 and Ground Drive Belt

Replacement , page 11.

26 3A3394BRepair - Parts

Engine Replacement

5.

Disconnect throttle cable.

Engine Replacement

Removal

1.

Remove clutch, see

Clutch Replacement , page 24.

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. ti19186a

3A3394BRepair - Parts ti19703a

27

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.

28 ti19686a

Engine Ground

Ignition

Voltage Regulator

Starter Solenoid

Battery 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.

3A3394BRepair - Parts

Touch-Pad Display

Touch-Pad Display

1

3

2

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)

3A3394BRepair - Parts

1

3 ti23924a

29

Control Board Replacement

Control Board

Replacement

Removal

1.

To disconnect power remove fuse, see Fuse

Replacement , page 34.

2.

Remove siphon tube(s) and lid(s).

5.

Remove four screws and remove pad.

LL250

DC

Shown

3.

Remove tank(s) from unit.

4.

Remove six screws and then remove front shield from unit.

6.

Remove six screws and control shroud. ti23930a ti19163a

30 ti23931a

3A3394BRepair - Parts

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 68. 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 34.

Check control, switches and display.

7.

Install splash shield with two screws.

ti24074a

Installation

1.

Install control board with eight mounting screws. ti2376a

8.

Install control shroud with six screws. See Removal

step 6.

9.

Install pad and tighten four screws. ti24075a

2.

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

3A3394BRepair - 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 3A3394BRepair - Parts

Battery Replacement

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.

NOTICE

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

4.

Disconnect two black wires from battery.

Battery Replacement

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.

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.

3A3394BRepair - Parts 33

Fuse Replacement

Fuse Replacement

1.

Remove fuse cover.

2.

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

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.

34 ti23941a

3A3394BRepair - 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

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.

3A3394BRepair - Parts

62

3

148

40 ti19700a

8.

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

35

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

36 3A3394BRepair - Parts

Steering Cable Replacement

Steering Cable Replacement

2.

Remove six screws and control shroud. Removal

1.

Loosen four screws and remove pad.

ti23930a ti23931a

3A3394BRepair - Parts 37

Steering Cable Replacement

3.

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

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.

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 3A3394BRepair - 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

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.

3A3394BRepair - Parts 39

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 ti19693a

37 36

2.

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

34

39 ti20125a

35

36

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

35

36

3.

Remove two spacers (36) and wheel (35) from fork

(34).

40 3A3394BRepair - Parts

Parking Brake Service

Parking Brake Service

Removal

1.

Remove tire, wheel hub, and fender. See, Wheel

Motor Removal , page 42.

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.

16

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 42.

5.

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

A

17

A

10

14

15

B

3A3394BRepair - Parts 41

Rear Wheel and Wheel Motors

Rear Wheel and Wheel Motors

Rear Wheel Removal

1.

Set LineStriper on blocks so wheels are off ground.

3.

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

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 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.

42

16 ti18588a

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

4.

Remove screw (6) and distance sensor (4) with clamp (5).

5.

Remove four bolts (78), lock nuts (79) from fender

(19).

21b

56 ti23945a

6.

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

3A3394BRepair - 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).

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 13.

Wheel Sensor Replacement

Removal

1.

Loosen four screws and remove pad.

ti19328b

3A3394BRepair - Parts 43

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.

44 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

3A3394BRepair - Parts

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.

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.

Refill gas tank. See engine manual.

Move fuel shut-off lever to ON position.

, page 68.

Engine oil level is low.

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.

Turn engine clutch switch ON.

Close wheel motor bypass valve to engage drive. See

Operation manual

Hydraulic fluid is low.

Drive cable is disconnected or broken.

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.

Shut off striper and add fluid*.

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.

3A3394BRepair - Parts 45

Troubleshooting

Engine operates, but displacement pump does not operate

Low stall or run pressure shown on display

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 12.

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.

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.

Bring sprayer to Graco distributor for repair.

Clean strainer

Suction tube air leak.

Drain line to paint hopper is clogged.

Intake valve is leaking.

Pump packings are worn.

Paint is too thick.

Tighten suction tube

Clean drain line

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

Replace pump packings. See Pump manual.

Engine speed is too high.

Pressure setting too low.

New pump or new packings.

Faulty transducer.

Thin the paint according to supplier recommendations.

Decrease throttle setting before priming pump. See

Operation manual.

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

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

Replace transducer.

46 3A3394BRepair - Parts

Troubleshooting

Excessive paint leakage into throat packing nut

Problem

Fluid is spitting from gun

Cause

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.

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

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.

Bad sensor, both pumps.

Distance not adding properly

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

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.

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.

Pressure control knob rotates freely with no pressure change

Set screw at hydraulic pump connection is loose.

Remote cable is broken or disconnected.

Solution

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 34.

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.

3A3394BRepair - Parts 47

Troubleshooting

Problem

Gun does not trigger

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).

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.

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 48.

Reload the correct pattern.

Perform calibration routine (see Operation manual).

PARKING LAYOUT Mode

Gun does not apply dots

Gun selector switch is OFF

Dot size setting is too small

Turn gun selector switch ON.

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)

48 3A3394BRepair - Parts

Notes

Notes

3A3394BRepair - Parts 49

Parts

Parts

50

149

*179

*99

*179

*102

*100 55 248

223

278

186

204

226

144 124

8

179

145

122

200

101

7

185

*LLV 250DC only

179

100

193

189b

189a

6

191

192 189

261 190

236

194

189c

191

334

235

234

335

199

336

102

179

80

55

52

167

239

161

237

265

179

33

223

222

220 273

238

187

274

116

264

151

150

188 ti23185c

3A3394BRepair - Parts

Parts List

Ref.

Part Description

6

7

8

33

52

55

80

260212 SCREW, hex washer hd, thd form

16M279 BUMPER, platform

100101 SCREW, cap, hex hd

101566 NUT, lock

111145 KNOB, pronged

100023 WASHER, flat

120721 SCREW, cap, 3/8-16, hexhd

99 16W544 BRACKET, mount, second pump,

LL250, paint

100 16M717 BRACKET, mount, pump, LL250, paint

101 111801 SCREW, cap, hex hd

102 107210 SCREW

116 102040 NUT, lock, hex

122

*191239 HOSE, coupled 3/8 x 11 ft

**124884 HOSE, coupled 3/8 x 22 ft

124 108851 WASHER, flat

144 126108 SCREW, shoulder, skt hd

145 24L909 FRAME, platform, painted, LL250

149 278421 PAD, foam

150 115753 BATTERY, 33 AH, sealed

151 801972 PAD, battery

161 118444 SCREW, mach, slot hex wash hd

167 24D618 PIN, handle, Grindlazer

179 111192 SCREW, cap flang hd

185 290159 LABEL, reflective

186 114271 STRAP, retaining

187 237686 WIRE, ground assembly w/ clamp

188 126071 STRAP, battery

189 16W372 MANIFOLD, hydraulic, three piston

189a 24N577 KIT, repair, coil, hydraulic manifold

189b 24N490 KIT, repair, solenoid

(includes 189a)

Qty.

6

2

2

2

1

4

1

2

2

1

1

1

1

2

1

12

1

1

1

1

1

1

1

2

2

2

1

1

8

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

1

4

1

1

1

6

1

3

3

1

3

1

1

1

2

2

3

1

1

3

3

* LLV 250DC

** LLV 250SPS

Parts

3A3394BRepair - Parts 51

Parts

Parts

52

301

99

88 137

138 87

21

26

29 22

23

207

135

206

135

205

36

90

89

90

36

40

3

136

148 27

3

39

37

98

33

40

97

25 34

30

212

33

263

303

302

305

304

32

28 24

301

303

211

160

161

52

(

214

See Page 8)

169

48

131

86

168

184

141

284

178

283

85 ti23186a

275

83

3A3394BRepair - Parts

Parts List

87

88

89

90

97

98

39

40

48

52

33

34

36

37

83

85

86

Ref.

Part

27

28

29

30

31

32

3

21

22

23

24

25

26

Description

102393 NUT, lock

116424 NUT

100022 SCREW, cap, hex hd

102040 NUT, lock

115480 KNOB, T-handle

118886 GROMMET, isolator

108868 CLAMP

127372 BUSHING

159346 WASHER

16X072 BRACKET, control, mount

24U233 CABLE, 18 conductor

24U234 BOX, control

17B211 COVER, control box, LL250, painted

116477 WASHER, flat, nylon

116038 WASHER, wave, spring

193658 SPACER, seal

113471 SCREW, cap, hex hd

112405 NUT, lock

125792 BALL, joint, rod end

16M273 CABLE, steering push/pull, LL250

111145 KNOB, pronged

113677 BUSHING, nylon

107257 SCREW, thd forming

24N494 KIT, repair, support, steering

(includes 89, 90)

24L900 BAR, handle, LL250

120151 RETAINER, caplug

113485 BEARING, cup/cone

115503 SEAL, grease

119569 BUSHING, strain relief

119554 NUT, lock, nylon, thin pattern

Qty.

2

1

1

1

2

2

2

1

1

2

1

1

2

1

2

2

3

1

2

2

1

1

3

2

1

4

2

3

6

1

Ref.

Part Description Qty.

99 24M196 HANDLE, control, forward/reverse 1

131 112798 SCREW, thread forming, hex hd

135 119532 BEARING, flanged

1

2

136 15E780 PIN, fork

137 15K162 BLOCK

138 16N401 SWITCH, push button

141 16M702 FRAME, upright, LL250, paint

1

1

1

1

1 148 16M274 CABLE, forward/reverse, push/pull

160 16X069 COVER, display, LL250, painted

161 118444 SCREW, mach, slot hex wash hd

168 24N496 KIT, repair, shield, paint

(includes 169)

1

6

1

169 114225 TRIM, edge protection

178 107439 SCREW, mach, hex hd

184 127372 BUSHING, strain relief

205 178342 CLIP, spring

206 C20004 SCREW, cap

207 114659 GRIP, handle

211 16X127 LABEL, brand, LineLazer, dash

212 16X125 LABEL, brand, LineLazer, top

214 24U235 PLATE, control complete, see page 8

263 16N548 GASKET, control

275

283

284

301

302

303

304

305

126215 TRIM, edge, protection

16P554 PLATE, cover, control board

16M007 SCREW, drill, hex washer head

24V564 KIT, board, toggle switch

24V565 KIT, display, repair

24V566 KIT, switch, membrane

16Y924 SPACER, toggle switch

127543 SEAL, toggle switch

1

1

1

2

1

1

1

1

6

1

1

2

1

3

3

1

1

1

Parts

3A3394BRepair - Parts 53

Parts (24U235 Control Panel)

Parts (24U235 Control Panel)

4

5 10 159

157

11

156

3

158

153

1

2

9

7

6 8

10

152

154 ti23976a

54 3A3394BRepair - Parts

Parts (24U235 Control Panel)

Parts List

Ref. Part Description

1

2

16X077 PLATE, control, LL250

24V561 KIT, repair, control board (includes

9)

16X074 LABEL 3

4

5

8

9

6

7

17C063 SWITCH, rocker, SPST

16M508 CABLE, choke

16M509 CONTROL, throttle

16N549 GASKET, throttle

109466 NUT, lock, hex

111839 SCREW, mach, pnh, sems

10 16X075 SWITCH, ignition

Qty.

1

1

2

8

1

1

1

1

1

1

Ref. Part Description

11 17C064 WIRE, positive

152 16Y411 BUSHING, pressure control mount

153 119775 NUT, panel

154 24V563 SHAFT, flexible

156 115999 RING, retaining

157 16Y408 KNOB, pressure control

158 101962 SCREW, set, sch, 1/4-20

159 15A464 LABEL, control

Qty.

1

1

1

1

1

1

1

1

24U235 PLATE, control (includes 1, 2, 3, 4,

5, 6, 7, 8, 9, 10, 11)

1

3A3394BRepair - Parts 55

Parts

Parts

6

242

54

282 126

300

301

302

127

65

158

70

55

81

213

219

191

3

166

62

82

55

22

63

40

140

139

140

166

77

55 75

82

190

124

275

242

76

9

125

83

55

33

6

84

282

60

81

6

61

58

66

67

78

64

71

59

57

56

79

68

53

51

80

55

54a

6

5

85

33

1

241

55 ti19069a

56 3A3394BRepair - Parts

Parts List

Ref.

Part Description

1

3

5

6

9

22

33

40

51

53

54

24L896 FRAME, painted, LL250

102393 NUT, lock

108868 CLAMP, wire

260212 SCREW, hex washer hd, thd form

111040 NUT, lock, insert, nylock, 5/16

16M271 HOSE, coupled, assembly, LL250

101566 NUT, lock

125792 BALL, joint, rod end

114982 SCREW, cap, flng hd

16M072 FRAME, mount, engine, paint

24V562 KIT, repair, engine, GX390

(includes 54a, 60, 202, 241)

71

75

76

77

78

66

67

68

70

58

59

60

61

62

54a 24N502 KIT, repair, rectifier, voltage

55 100023 WASHER, flat

56

57

16M075 SPACER, clutch, 1.00 id x .5 thk

125877 CLUTCH, electric, LL250

16M076 WASHER, 7/16 id x .25 thk

116596 SCREW, cap, hex head

125919 KEY, parallel, square, 1/4

16M077 PULLEY, double

24N499 KIT, repair, bracket, hydro pump

(includes 75, 76, 77, 242)

247930 KIT, repair, hydraulic pump 63

64

65

16M078 PULLEY, 5 o.d. x 15mm

125793 BELT, vee, tri-power, AX44

125876 BELT, vee, tri-power, AX26

117222 KEY, square

16M084 TRAY, hyd reservoir, LL250, paint

16U205 PULLEY, fan

120087 SCREW, set, 1/4 in. x 1/2 in.

100678 SCREW, cap hex hd

100521 SCREW, cap hex hd

110996 NUT, hex, flange head

16M082 BRACKET, clutch, anti-rotation

Qty.

2

3

8

2

1

1

1

1

1

1

4

1

1

1

1

1

1

11

1

1

1

1

1

1

1

1

1

1

2

2

1

1

Ref.

Part Description

79

80

81

112406 SCREW, cap, hex hd

120721 SCREW, cap, 3/8-16, hexhd

108481 SCREW, cap, hex hd

82

83

84

100004 SCREW, cap, hex hd

113677 BUSHING, nylon

16M715 BRACKET, mount, belt guard,

LL250

107257 SCREW, thd forming 85

124 108851 WASHER, plain

125 119695 DAMPENER, engine mount

126 24N498 KIT, repair, guard, belt

(includes 6, 127, 242, 282, 300)

127 117284 GRILL, fan guard

139 15R309 ROD, standoff, 1/4 in. od x

2.75 in. LG

140 111006 SCREW, cap

158 101962 SCREW, set, 1/4-20

166 16M276 HOSE, coupled, feed line, LL250

190 124941 FITTING, long elbow, hydraulic

191 116829 FITTING, 90 degree

202 126072 KIT, Honda remote choke

(not shown)

213 16X126 LABEL, brand, LineLazer, DC, side

219 189892 LABEL, Graco logo

241  194126 LABEL, warning

242  16M768 LABEL, pinch hazard iso

275 126215 TRIM, edge, protection

282 16P547 PLATE, backer, belt guard, paint

300 260387 SCREW, pan hd, x recess

301 116876 WASHER, flat

302 116969 NUT, lock

1

1

1

4

4

1

1

1

1

2

2

2

4

4

2

4

2

1

1

1

Qty.

6

1

1

2

7

5

1

 Replacement warning labels may be ordered free of charge.

Parts

3A3394BRepair - Parts 57

Parts

Parts

247

175

174**

284

281

285

245

292 290

287

320

164

162 154

163

325

321

320

147

311

333

310

313

282

332

191

312

246

121

246 284

174*

329

327

326

308

191

314

316

317

315

191

218

309

307

305

191

306

303

301

334

302 ti28184a

* LLV 250DC

**LLV 250SPS

58

72

3A3394BRepair - Parts

Parts List

Ref.

Part Description

52 111145 KNOB, pronged

72 125794 SCREW, taptite, hex washer hd

121 181072 KIT, repair, strainer

128 16X081 BRACKET, dual tank retaining

144 126108 SCREW, shoulder, socket head

147 124770 FITTING, #8 jic tee, swivel

154 24V563 KIT, repair, shaft, flexible

(includes 162)

162 112303 SCREW, set, sch

163 15C958 GUARD, control, pressure

164 112166 SCREW, cap, sch

174

*278720 RESERVOIR, 15 gallon

**278452 RESERVOIR, 25 gallon

175 24V687 KIT, pail, lid assembly

191 116829 FITTING, 90 degree

217 15K440 LABEL, brand, GH/EH cooling

218 16P142 LABEL, hydraulic only icon

245 114967 COUPLING, pipe, 1 in.

246 189674 TUBE, intake

247 127375 PLUG, 3”

254  189285 LABEL, caution

281 15F149 TUBE, suction

282 194306 HOSE, fluid

283 198119 FITTING, elbow, barbed

284 101818 CLAMP, hose

285 278722 GASKET, pail

287 16X071 TUBE, drainline

290 248008 HOSE, cpld, 1/4 in. x 44 in.

292 196180 BUSHING

301 15J513 TANK, reservoir, blue

Qty.

1

1

2

2

2

2

2

2

1

1

2

2

2

4

2

2

1

2

2

2

1

2

2

1

1

2

4

2

1

Ref.

Part Description

302 101754 PLUG, pipe

303 120604 GASKET, reservoir

305 24K967 TUBE, supply, hydraulic

306 116919 FILTER

307 15E587 TUBE, suction

308 154594 PACKING, o-ring

309 16M160 COVER, reservoir, LL250, painted

310 107188 PACKING, o-ring

311 156401 PACKING, o-ring

312 16M112 TUBE, suction, hydraulic, LL250

313 119426 SCREW, mach, hex washer hd

314 120726 CAP, breather, filler

315 198841 RETAINER, ball, pressure bypass

316 100084 BALL, metallic

317 116967 SPRING, compression

320 16X083 KIT, repair, pump, 250SPS

(includes 310, 311, 332)

321 110792 FITTING, elbow, male, 90 deg

325 17A581 KIT, repair, case drain

(includes 308)

326 17A582 TUBE, hydraulic case, drain

327 246173 KIT, repair, oil filter (includes 315,

316, 317)

329 127686 FITTING, tee

332 117471 SCREW, mach, hex flat head

333 120184 FITTING, hydraulic

334 116618 MAGNET

Qty.

1

1

1

1

1

1

8

4

1

1

1

2

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

Parts

3A3394BRepair - Parts 59

Parts (Front Wheel)

Parts (Front Wheel)

Series A

Series B

257

243

31

47

46

43

15

43

44

258

185

30

55

142

29

40

34

3

37

39

1

36

243

55

31 47

46

45

43

30

258

143

257

1

135

136

136

55

142 29 185

40

37

34

3

43

44

137

42

138

41

36

39

35

36

35 ti19066b ti27030a

60 3A3394BRepair - Parts

Parts (Front Wheel)

Parts List - Series A

Ref.

Part Description

1

3

15* 15V264 SPRING, extension

29 113743 SCREW, cap, hex hd

30

24L896 FRAME, painted, LL250

102393 NUT, lock

31

24L902 ADJUSTER, caster, weldment,

LL250

126204 SCREW, cap, hex hd

34

35

24L897 CASTER, painted, LL250

16W284 WHEEL, foam filled (LL250 SPS,

DC)

36

37

39

40

193658 SPACER, seal

113471 SCREW, cap, hex hd

112405 NUT, lock

125792 BALL, joint, rod end

41* 125893 WASHER, thrust, 1-1/2 in. id

42* 16M267 LEVER, self centering, LL250

43

44

126112 BEARING, tappered 1 1/4, cone

125892 SEAL, bearing, 1-1/4 shaft

45

46

47

55

126064 SHIM, caster

125890 NUT, 1 1/4-12 unf

126063 CAP, dust

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

Qty.

1

2

1

2

1

1

1

1

1

1

2

2

1

1

4

2

1

2

1

2

2

1

2

2

1

Parts List - Series B

Ref.

Part Description

1

3

29

30

24L896 FRAME, painted, LL250

102393 NUT, lock

113743 SCREW, cap, hex hd

24L902 ADJUSTER, caster, weldment,

LL250

31

34

35

126204 SCREW, cap, hex hd

24L897 CASTER, painted, LL250

16W284 WHEEL, foam filled (LL250 SPS,

DC)

193658 SPACER, seal 36

37

39

113471 SCREW, cap, hex hd

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

45

125892 SEAL, bearing, 1-1/4 shaft

126064 SHIM, caster

46

47

125890 NUT, 1 1/4-12 unf

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.

2

1

1

2

1

1

1

2

1

4

1

1

1

1

2

1

2

2

4

2

1

1

1

1

1

2

2

1

2

3A3394BRepair - Parts 61

Parts (Gun Mount)

Parts (Gun Mount)

173

229a

229b

171

226

227

52

86

11

50

229

229 172

172f

172b

172

33

90

9 52

49

52

172c

172d

236

199

172j

170

228

116

312

310

87

89

88

32

311

18

229c

172n

172m

172g

172h

172k

172a ti28185a

62 3A3394BRepair - Parts

Parts (Gun Mount)

Parts List

Ref.

Part Description

52

86

87

88

9

11

111040 NUT, lock, insert, nylock, 5/16

24N170 BRACKET, mount, pointer complete

24N171 ARM, pointer, complete 18

32

33

16C943 INDICATOR, pointer

101566 NUT, lock

49 24N350 BRACKET, gun arm

50  16P136 LABEL, injection read manual iso

111145 KNOB, pronged

114653 SCREW, cap, flange hd

114965 WASHER, spring, wave

114685 COLLAR, screw, set

89

90

114966 KNOB, pronged

100527 WASHER, plain

116 102040 NUT, lock, hex

170 17J407 BRACKET, support gun

171 24Y645 KIT, clamp

172 24M638 BAR, gun holder, LLV 250

SPS

&

250

DC

Qty.

4

2

2

2

3

1

2

4

2

2

3

4

1

2

1

2

4

Ref.

Part Description

172c 17J145 ARM, holder, gun

172d 119647 SCREW, cap, socket, flthd

172f 15F750 KNOB, holder, gun

172g 15F209 STUD, pull, trigger

172h 24Y991 KIT, pivot

172j 16N788 STUD, cable, gun, circlip

172k 119664 BEARING, sleeve

172m 15F214 LEVER, actuator

172n 24Y991 KIT, pivot

173 248157 KIT, accessory, gun, flex

199 16M671 CABLE, gun, solenoid

226 245798 KIT, repair, hose

227 188135 GUIDE, cable

228 17J406 BRACKET, support, extension

229 17J424 EXTENSION, vertical gun arm

236 126111 RETAINER, circlip, external, 8mm

310 16Y445 CHAIN, indicator

311 116252 SCREW, #10 tapping, Phillips

312 120317 NUT, wing

Qty.

1

2

2

2

2

2

1

1

2

2

2

2

1

1

1

1

1

2

1

172a 287569 KIT, repair, gun holder (includes

172f, 172k)

172b 16M850 BRACKET, cable, gun,

1

1

Replacement warning labels may be ordered free of charge.

3A3394BRepair - Parts 63

Parts

Parts

255

16

17

10

12

27

2ref

28

26

6

5

4

13

15 14

25

20

19

2 22 21

259

146 ti19068b

64 3A3394BRepair - Parts

Parts List

Ref.

Part

13

14

15

16

17

19

5

6

2

4

10

12

Description Qty.

125929 MOTOR, wheel

15K357 SENSOR, distance

108868 CLAMP, wire

260212 SCREW, hex washer hd, thd form

24M214 BRACKET, plate, pivot, brake, LL250 1

16M656 PIN, brake 4

1

1

2

1

126073 RING, retaining, e ring, 1/2 dia

24M215 BRACKET, lock, brake, LL250

15V264 SPRING, extension

16M743 PEDAL, brake, LL250

112785 SCREW, hex hd, flanged

16M753 FENDER, wheel, right, LL250, paint

1

1

1

1

4

1

Ref.

Part Description

20

21

22

25

26

114766

245340

BOLT, cap hex head

801020 NUT, lock, hex

16M271 HOSE, coupled, assembly, LL250

24N508 KIT, repair, hub and gear assy

KIT, repair, tire

27

28

125481 NUT, wheel, 1/2-20

100104 PIN, cotter

146 16N394 FENDER, wheel, left, LL250, paint

255  16P141 LABEL, parking brake icon

259  16P139 LABEL, multiple hazard iso

 Replacement warning labels may be ordered free of charge.

Qty.

2

2

8

2

8

8

2

1

1

1

Parts

3A3394BRepair - Parts 65

Parts (Pump)

Parts (Pump)

366

119

367

368

369

370

118

347

366

371

346

364

380

379

378

377

387

94

95

122

95

94

307

226

389 388

386

385

384

363

115

114

376

390

95

391

392

123

120

112

116

113

107

356

354

353

346

345

344

343

393

117

102

103

104

106

105

95

123

372

370 ti19074b

66 3A3394BRepair - Parts

Parts (Pump)

Parts List (Pump)

Ref.

Part Description

94* 196179 ELBOW, street

95* 196178 ADAPTER, nipple

102 107210 SCREW

103 287186 KIT, repair, magnet

104 116551 RING, retaining

105 197443 PIN, pump

106 193394 NUT, retaining

107 277068 KIT, repair, pump 200HS

(includes 95, 103, 104, 105)

112 119720 SWITCH, reed w/connector

113 114528 SCREW, mach, phillips, pnhd

114 15F911 GUARD, pump rod

115 100058 SCREW, cap, hex hd

116 102040 NUT, lock, hex

117  15H108 LABEL, pinch point

118 15B804 LABEL, Graco logo

119  15B063 LABEL

120 24V064 KIT, repair, suction hose

122 191239 HOSE, coupled, 3/8 in. x 11 ft

123 245797 KIT, repair, hose

226 245798 HOSE, coupled, 1/4 in. x 7 ft

307* 15G331 PLUG, pipe

343 117739 WIPER, rod

344 112342 NUT, jam

345 112561 PACKING, block

346 117283 PACKING, o-ring

347 288754 KIT, repair, trip rod/piston (includes

118, 119)

353 108014 PACKING, o-ring

354 178226 SEAL, piston

356 178207 BEARING, piston

Qty.

1

1

1

1

1

2

4

4

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

2

1

Ref.

Part Description

363 246176 SLEEVE, hydraulic, cylinder

(includes 346)

364 15A726 NUT, jam

366 117607 FITTING, elbow std thd

367 106276 SCREW, cap, hex head

368 155685 PACKING, o-ring

369 178179 WASHER, sealing

370 100139 PLUG, pipe

371 15F519 TUBE, hydraulic, supply

372 119841 FITTING, tee, branch

376* 15H561 MANIFOLD

377* 24V455 FILTER, 50 mesh, ultra

378* 15C766 TUBE, diffusion

379* 117285 PACKING, o-ring

380* 287285 KIT, repair, filter cap

(includes 378, 379)

384* 193710 SEAL, seat, valve

385* 193709 SEAT, valve

386* 245103 KIT, repair, drain valve

(includes 384, 385, 387, 388, 389)

387* 114708 SPRING, compression

388* 15G563 HANDLE, valve

389* 116424 NUT, cap

390* 111457 PACKING, o-ring

391* 24N516 KIT, repair, transducer

(includes 390)

392* 196181 FITTING, nipple

393 15A728 MANIFOLD, adapter

Qty.

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

2

1

1

1

1

1

* Included in Filter Repair Kit 24N517

Replacement warning labels may be ordered free of charge.

3A3394BRepair - Parts 67

Wiring Diagram

Wiring Diagram

68 ti23961b

3A3394BRepair - Parts

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

187

115753 BATTERY, 33 AH, sealed

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

2

1

1

1

1

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

1

1

1

1

1

1

1

3

1

1

1

3A3394BRepair - Parts 69

Hydraulic Diagram

Hydraulic Diagram

70 ti23962b

3A3394BRepair - Parts

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 1

189b 24N490 KIT, repair, solenoid

(includes 189a)

1

189c 24V560 KIT, repair, actuator piston 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

3A3394BRepair - Parts 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 B , March 2016

advertisement

Was this manual useful for you? Yes No
Thank you for your participation!

* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project

Related manuals