Graco 3A2593A - LineLazer IV 250SPS Self-Propelled Line Striper, Repair Owner's Manual

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Graco 3A2593A - LineLazer IV 250SPS Self-Propelled Line Striper, Repair Owner's Manual | Manualzz

Repair

LineLazer IV 250

SPS

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. Save these instructions.

Model Guns Description

24F307

24K960

2 Guns

1 Gun

LLIV 250SPS (North America,

Latin America, Asia Pacific)

LLIV 250SPS (Latin America,

Asia Pacific)

24K961 1 Gun LLIV 250SPS (Europe)

24K962 2 Guns LLIV 250SPS (Europe)

24M608 1 Gun

FieldLazer G400

(North America)

Related Manuals:

3A2090 Operation

3A2598 Parts

311254

309277

312307

Gun

Pump

Auto-Layout Applications Methods

3A2593A

EN ti17520a

2

Table of Contents

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

Component Identification . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . 12

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Oil Reservoir Pump Replacement . . . . . . . . . . . . 13

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

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

Hydraulic Gun Manifold Replacement . . . . . . . . . 15

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Paint Pump Replacement . . . . . . . . . . . . . . . . . . . 17

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Hydraulic Motor Replacement . . . . . . . . . . . . . . . 18

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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

Clutch Replacement . . . . . . . . . . . . . . . . . . . . . . . 19

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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

Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . 21

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Touch-Pad Replacement . . . . . . . . . . . . . . . . . . . . 23

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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

Control Board, Toggle Switches and Display

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . 27

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 28

Forward/Reverse Cable Replacement . . . . . . . . . 29

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Steering Cable Replacement . . . . . . . . . . . . . . . . 31

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Front Wheel Replacement . . . . . . . . . . . . . . . . . . . 33

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Parking Brake Service . . . . . . . . . . . . . . . . . . . . . . 34

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Rear Wheel and Wheel Motors . . . . . . . . . . . . . . . 35

Rear Wheel Removal . . . . . . . . . . . . . . . . . . . . 35

Rear Wheel Installation . . . . . . . . . . . . . . . . . . . 35

Wheel Motor Removal . . . . . . . . . . . . . . . . . . . . 35

Wheel Motor Installation . . . . . . . . . . . . . . . . . . 36

Wheel Sensor Replacement . . . . . . . . . . . . . . . 36

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Wiring Parts List . . . . . . . . . . . . . . . . . . . . . . . . 43

Hydraulic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 44

Hydraulic Parts List . . . . . . . . . . . . . . . . . . . . . . 45

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 48

3A2593A Repair

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.

• Keep work area free of debris, including solvent, rags and gasoline.

• 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.

3A2593A Repair 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.

• Pressurized 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.

3A2593A Repair

Warnings

WARNING

BATTERY SAFETY

The battery may leak, explode, cause burns, or cause an explosion if mishandled.

• 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.

3A2593A Repair 5

6

Component Identification

Component Identification

1.

16.

15.

17.

2.

14.

1 3 .

12.

3 .

4.

5.

6.

1 Operator Platform

2 Paint Filter

3 Prime / Drain Valve

4 Displacement Pump

5 Rear Gun Arm Mount

6 Serial Label

7 Gun Trigger Safety

8 Wheel Motor Bypass Valve

9 Straight Line Adjuster

11.

9.

10.

OFF

ON

8 .

7.

10 Engine ON/OFF Switch

11 Hydraulic Fill Cap / Dipstick

12 Hydraulic Oil Filter

13 Paint Hopper (25 gallon / 95 liter)

14 Handle Bar Height Adjustment Knob

15 Engine Recoil Handle

16 Brake

17 Steering Handle ti15841a

3A2593A Repair

Component Identification (Controls)

Component Identification (Controls)

5.

4.

6.

3.

2.

7.

1

2

8.

1

2

9.

10.

1.

on off

11.

ti18719a

1 Hydraulic Pump Valve

2 Gun Trigger Control

3 Forward / Reverse Lever

4 Display

5 Engine Throttle

6 Engine Choke

7 Gun 1 Selector

8 Gun 2 Selector

9 Engine Kill / Main Power Switch

10 12V Accessory Jack

11 Pressure Control

3A2593A Repair 7

8

Grounding Procedure (For Flammable Materials Only)

Grounding Procedure

(For Flammable Materials Only)

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

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.

Ground sprayer with 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 pump valve OFF . Turn engine OFF .

ti3306a ti6740a

3.

Turn pressure control to lowest setting. Trigger gun to relieve pressure.

ti 33 05 a ti3441a

PAINT

4.

Engage gun trigger safety. Turn prime valve down. ti 33 24 a ti6473a

3A2593A Repair

Ground Drive Belt

Replacement

Removal

1.

Loosen four screws and remove belt cover.

Installation

1.

Install belt onto pulleys.

Ground Drive Belt Replacement ti19134a

2.

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

ti19128a

2.

Loosen two hold-down bolts.

ti19130a

3.

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.

4.

Remove belt. ti19131a ti19129a

4.

Replace belt cover and tighten four screws. ti19133a ti19128a

3A2593A Repair 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 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 page 9).

10 3A2593A Repair

Hydraulic System Purging

Hydraulic System Purging

5.

Turn on the Main Power Switch to engage clutch.

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.

ti18552a

6.

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

ti18718a

2.

Fill oil reservoir to “Full” range.

ti18587a

Full Range (cold)

ti343 1 a

3.

Make sure drive wheel release is closed (+).

+

4.

Start engine and run at low speed.

ti18576a

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.

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. ti6473a on off ti19669a

8.

The hydraulic gun manifold is self-purging.

9.

Turn engine off and check oil level. Top off to “Full” range.

ti343 1

Full Range (cold)

ti18562a

3A2593A Repair 11

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,

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 ten-

sion (see page 9).

7.

Purge Hydraulic System

, page 11.

71

60

63

71

64

62

3

55 ti19135a

82

40

12 3A2593A Repair

Oil Reservoir Pump

Replacement

Oil Reservoir Pump Replacement

6.

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

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 and Oil Reservoir Belt, page

10.

2.

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

ti19672a

Installation

1.

Install pump onto oil reservoir cover with four screws. ti19139a

3.

Loosen nut and slide cable sleeve down to gain access to cable set screw.

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.

ti19144a

4.

Remove set screw and cable. ti19142a

5.

Remove eight screws and oil reservoir cover with pump.

ti19140a

3.

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

3A2593A Repair ti19140a ti19670a

13

Oil Reservoir Pump Replacement

4.

Install cable and tighten set screw. 6.

Connect three hydraulic hoses to fittings on oil reservoir. Replace oil filter.

5.

Slide cable sleeve up and tighten screw. ti19143a ti19145a ti19139a

7.

Install and tension Oil Reservoir Belt

(page 10)

and Ground Drive Belt

(page 9).

8.

Purge hydraulic system, page 11.

14 3A2593A Repair

Hydraulic Gun Manifold

Replacement

Hydraulic Gun Manifold Replacement

6.

Label wire harnesses GUN 1 and GUN 2 . Disconnect two wire harnesses from solenoids.

Gun 2

Gun 1

Removal

1.

Remove tank lid and siphon tube. ti19161a

7.

Label gun cables Gun 1 and Gun 2. Disconnect gun cables from actuators.

ti19166a

2.

Remove tank from unit.

3.

Remove six screws from front shield.

Gun # ti19159a

8.

Use a needle-nose pliers to remove gun cables from bracket.

ti19163a

4.

Remove front shield from unit.

5.

Loosen four screws and remove pad.

ti19667a

9.

Use wrench to disconnect manifold tubes by the paint pump. NOTE: Oil will spill. Use a rag to contain the oil. ti19164a

3A2593A Repair ti19160a

15

Hydraulic Gun Manifold Replacement

10. Disconnect manifold tubes at manifold.

11. Remove two mounting bolts and slide hydraulic manifold down and out from unit.

4.

Push Gun 1 and Gun 2 gun cables into bracket.

NOTE: Be sure to connect Gun 1 cable to the hole in the bracket closest to center of sprayer.

5.

Connect Gun 1 and Gun 2 cables to actuators.

ti19162a

Installation

1.

Slide hydraulic manifold in and up into unit. Install and tighten two mounting bolts. ti19159a

6.

Connect two wire harnesses to solenoids.

NOTE: Be sure to connect Gun 1 to coil closest to center of sprayer.

Gun 2

Gun 1 ti19162a

2.

Loosely install manifold tubes to manifold.

3.

Loosely install manifold tubes by the paint pump.

Tighten four nuts.

ti19161a

7.

Install pad and tighten four screws.

8.

Install front shield to unit and tighten six screws.

9.

Install tank into unit and connect siphon tube.

NOTE: The hydraulic gun manifold is self-purging. ti19160a

16 3A2593A Repair

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).

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 (approximately 45°) to clear ball valve hose.

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

116

114

106

95

123

105 ti19138a

107

120

104

109

197

110

3A2593A Repair 17

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

, page 17.

3.

Disconnect fitting (108) above ball valve (109).

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

4.

Disconnect hose (111) and fitting (193) from fitting

(196).

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 (111) and fitting (193) to fitting (196).

4.

Connect fitting (108) above ball valve (109).

5.

Install Paint Pump

, page 17.

6.

Purge hydraulic system, page 11.

196

113

193

111

112 116

108

109 ti19688a

110

18 3A2593A Repair

Clutch Replacement

Removal

1.

Remove Ground Drive Belt,

page 9.

2.

Remove Oil Reservoir Belt

, page 10.

3.

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

Clutch Replacement

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.

ti19697a

8.

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

56

57

59

58

60 ti19214a

9.

Disconnect clutch connector to main wire harness.

ti19213a

6.

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

61

81 ti19212a ti19216a

3A2593A Repair 19

Clutch Replacement

Installation

1.

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

Slide clutch (57) onto crankshaft.

56

57

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.

6.

Connect clutch to wire harness. ti19704a 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.

ti19212a

7.

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

58

59 ti19692a

20 ti19908a

8.

Install and tension Oil Reservoir Belt

(page 10)

and Ground Drive Belt

(page 9).

3A2593A Repair

Engine Replacement

Engine Replacement

5.

Disconnect choke cable.

Removal

1.

Remove Clutch

, see page 19.

2.

Disconnect all wires from engine. ti19185a

6.

Tie knot in rope by recoil starter to prevent rope from being pulled into recoil starter.

7.

Take rope handle apart and untie knot in recoil starter handle.

3.

Remove air filter cover, element and base. ti15307a ti19188a

8.

Pull rope through rope guide.

9.

Remove four mounting bolts from engine.

ti19186a

4.

Disconnect throttle cable. ti19187a

10. Remove engine. NOTE: Engine voltage regulator is located below engine mounting plate. Remove two screws and disconnect wires. ti19183a

3A2593A Repair ti19703a

21

Engine Replacement

Installation

1.

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

Tighten screw on hex-shaped pivot.

e.

Verify proper operation of engine choke.

ti19706a

2.

Install engine and tighten four mounting bolts and nuts.

ti19686a

6.

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. ti19187a

3.

Use compressed air to feed recoil starter rope through rope guide. ti19690a

7.

Install air filter base, element and cover.

ti19708a

4.

Feed rope through recoil starter handle and tie knot.

ti19186a

8.

Connect three wires to engine.

1 in. (25 mm) ti20066a

5.

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.

22 ti19668a

9.

Install Clutch

, see page 19.

10. Add gas and oil to engine (see Operation manual).

11. Start engine and verify high speed of 3600 rpm.

3A2593A Repair

Touch-Pad Replacement

Touch-Pad Replacement

Removal

1.

Remove six screws and control shroud.

Installation

1.

Apply touch-pad to sheet metal.

2.

Connect ribbon cable from touch-pad at display board.

ti19098a

2.

Disconnect ribbon cable from touch-pad at display board. ti19910a

3.

Install control shroud with six screws.

ti19910a

3.

Peel off touch-pad and remove adhesive from sheet metal. ti19098a

3A2593A Repair 23

Control Board, Toggle Switches and Display Replacement

Control Board, Toggle

Switches and Display

Replacement

Removal

1.

Remove Fuse

to disconnect battery, page 28.

2.

Remove tank lid and siphon tube.

7.

Remove six screws and control shroud. ti19098a

8.

Remove two screws and splash shield. ti19166a

3.

Remove tank from unit.

4.

Use wrench to remove six screws from front shield.

ti19701a

9.

Remove two toggle switch nuts from control panel. ti19163a

5.

Remove front shield from unit.

6.

Remove four screws and remove pad. ti19702a

10. Feed toggle switches through control panel.

24 ti19164a ti20244a

3A2593A Repair

Control Board, Toggle Switches and Display Replacement

11. If replacing the toggle switches loosen two screws holding the ferrite core. Disconnect cable and remove toggle switch board.

13. If replacing control board, disconnect all wires from control board. Remove eight mounting screws and remove control board.

ti20133a ti20135a ti19198a ti20136a

12. If replacing the display, remove two screws holding the ferrite core to toggle switch bracket. Pull apart ferrite core to remove from ribbon cable. Disconnect display ribbon cable from control board. Disconnect touchpad ribbon cable from display board. Remove four screws holding display and remove display. ti19199a

Installation

1.

If replacing control board, install control board with eight mounting screws. ti20133a ti20132a ti19199a

2.

Connect all wires to control board. See Wiring

Diagram

, page 42.

ti19910a ti20245a

3A2593A Repair ti19198a

3.

If replacing display, install display with four screws.

Install touchpad ribbon cable to display board.

Install display ribbon cable to control board. Assemble ferrite core on ribbon cable. Install ferrite core to toggle switch bracket with two screws.

4.

If replacing toggle switches, install toggle switches into toggle switch bracket. Make sure to place spacers between toggle switches and bracket. Connect cable to toggle switch board.

25

Control Board, Toggle Switches and Display Replacement

5.

Feed toggle switches through control panel and install two toggle switch nuts.

10. Install front shield and tighten six screws. ti19691a

6.

Install Fuse

, see page 28. Check control, switches

and display.

7.

Install splash shield with two screws.

ti19200a

11. Install tank, lid and siphon tube. ti19705a

8.

Install control shroud with six screws.

ti19170a

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

ti19098a

9.

Install pad and tighten four screws. ti19171a

26 3A2593A Repair

Battery Replacement

Removal

1.

Remove tank lid and siphon tube.

Battery Replacement

Installation

1.

Install battery.

NOTICE

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

2.

Connect red wire to positive (+) and black wire to negative (-) posts of the battery.

ti19166a

2.

Remove tank from unit.

3.

Use wrench to remove six screws from front shield.

ti19208a

3.

Install battery hold down strap. ti19163a

4.

Remove front shield from unit.

5.

Remove hold down strap from battery.

ti19162a

4.

Install front shield and use wrench to tighten six screws into shield.

ti19207a

NOTICE

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

6.

Disconnect two wires from battery. ti19200a

5.

Replace tank and install lid with siphon tube. ti19162a

7.

Remove battery.

ti19694a

3A2593A Repair 27

Fuse Replacement

Fuse Replacement

1.

Remove fuse cover.

2.

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

28 ti19209a

3A2593A Repair

Forward/Reverse Cable

Replacement

Forward/Reverse Cable Replacement

6.

At the handlebar, remove locknut (3) and ball joint

(40) from handlebar forward/reverse lever. Remove ball joint (40) from cable (148) and save if not replacing. Loosen two nuts on cable (148) and remove from bracket.

40

3

Removal

1.

Remove tank lid and siphon tube.

148 ti19166a

2.

Remove tank from unit.

3.

Use wrench to remove six screws from front shield.

ti19699a

7.

At the ground drive pump, remove locknut (3) and ball joint (40) from ground drive pump. Remove ball joint from cable and save if not replacing. Loosen two nuts on cable (148) and remove from bracket

(62).

62

3

148 ti19163a

4.

Remove front shield from unit.

5.

Loosen four screws and remove belt cover.

40 ti19700a

8.

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

3A2593A Repair ti19128a

29

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).

3.

Install cable (148) into handlebar bracket and tighten two nuts. Install ball joint (40) onto cable.

Install ball joint into handlebar forward/reverse lever and tighten locknut (3).

40

3

148

62

148

40 ti19700a

3 ti19699a

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.

7.

Use wrench to tighten six screws into front shield.

8.

Install tank onto unit.

9.

Install siphon tube and tank lid.

30 3A2593A Repair

Steering Cable

Replacement

Steering Cable Replacement

7.

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

Removal

1.

Remove tank lid and siphon tube. ti19166a

2.

Remove tank from unit.

3.

Use wrench to remove six screws from front shield. ti18550a

8.

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

40

48 ti19163a

4.

Remove front shield from unit.

5.

Loosen four screws and remove pad.

ti19164a

6.

Remove six screws and control shroud. ti19695a

9.

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

10. 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. ti19098a

3A2593A Repair 31

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

40

48

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).

ti19685a

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 ti19695a

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 locations noted in step 10 of Removal.

10. Verify straight line tracking and adjust if necessary

(see Operation manual).

11. Install control shroud and tighten six screws.

12. Install front shield onto unit.

13. Use wrench to tighten six screws into front shield.

14. Install tank onto unit.

15. Install siphon tube and tank lid.

32 3A2593A Repair

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

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.

Verify front tire pressure is 55-80 psi (380-550 kPa).

5.

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).

3A2593A Repair 33

Parking Brake Service

Parking Brake Service

Removal

1.

Remove tire, wheel hub, and fender. See Wheel

Motor Removal

, page 35.

2.

Remove clips (13) from three pins (A). Remove pins and levers.

16

16

A

A

Installation

1.

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

2.

Use screwdriver to install spring (15).

16

16

A

A

10

10

14

14

10

10

14

14

17

17

A

A

B

B ti19684a

13

3.

Use screwdriver to remove spring (15). Remove clip

(13) and pin (B).

4.

Replace damaged or worn parts.

17 17

A

A

B

B ti19684a

13

3.

Install levers (10, 16) with three pins (A) and clips

(13).

4.

Install fender, wheel hub, and tire. See Wheel

Motor Installation

, page 36.

5.

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

34 3A2593A Repair

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.

4

6

5

19

21a

79

56

22b

21b ti18584a

112

78

4.

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

(19).

5.

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

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).

3A2593A Repair 35

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 distance sensor (4) and clamp (5) with screw

(6).

4

6

5

19

21a

79

2.

Remove tank from unit.

3.

Use wrench to remove six screws from front shield and remove front shield from unit.

ti19163a

4.

Place jack under frame near pump-side wheel and raise jack.

5.

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

16

56

22b 112 ti18584a

21b

78

3.

Install wheel motor (21a) and fender (19) with four bolts (78) and lock nuts (79).

4.

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

(56).

5.

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

16

22 ti18589a

6.

Disconnect wheel sensor connector from wire harness. ti18589a

22

6.

Purge hydraulic system. See Hydraulic System

Purging

, page 11.

Wheel Sensor Replacement

Removal

1.

Remove tank lid and siphon tube.

ti19328a

7.

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

6

4 5

36 ti19166a ti19099a

3A2593A Repair

Rear Wheel and Wheel Motors

Installation

1.

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

(6).

6

5

4

5.

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

16

22 ti18589a

6.

Lower jack.

7.

Install front shield with six screws. ti19099a

2.

Connect wheel sensor connector to wire harness. ti19328a

3.

Verify sensor is working by turning on the main power switch and press SETUP to display the

MEASURE screen.

4.

Press gun trigger control button and rotate hub by hand exactly three turns. ti19200a

8.

Install tank and siphon tube. ti18564a ti19329a

NOTE: Sensor is working properly if the measure display reads 12.3 to 12.7 ft (3.75 to 3.87 m).

ti19170a

9.

Calibrate sprayer. See operation manual.

3A2593A Repair 37

Troubleshooting

Troubleshooting

General

Problem

Engine pulls hard

Engine will not start

High engine speed at no load

Machine will not drive

Engine operates, but displacement pump does not operate

Cause Solution

Excessive hydraulic load. Main power switch is on.

Engine is out of gas.

Fuel shut-off lever is OFF.

Engine switch is OFF.

Turn main power switch OFF.

Engine oil level is low.

Main power switch is stuck in engine stop 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.

Replace main power switch.

Oil is seeping into combustion chamber.

Improperly adjusted high speed setting.

Worn engine governor.

Main power switch is not turned ON.

Remove spark plug. Pull starter 2 to 4 times. Clean or replace spark plug. Start engine. Keep sprayer upright to avoid oil seepage.

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

Adjust or replace engine governor.

Turn main power switch ON.

Hydrostatic drive is not engaged.

Drive cable is disconnected or broken.

Refill gas tank. See engine manual.

Move fuel shut-off lever to ON position.

Turn engine switch ON.

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.

Main power switch is OFF.

Pump valve is OFF.

Pressure setting is too low.

Close wheel motor bypass valve to engage drive.

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.

Turn main power switch ON.

Turn pump 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 page 10.

Reverse tip to clean. See manual 311254.

Repair pump. See manual 309277.

Hydraulic motor not shifting.

Set pump valve OFF. Turn pressure down. Turn engine

OFF. Pry rod up or down until hydraulic motor shifts.

38 3A2593A Repair

Troubleshooting

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

Low stall or run pressure shown on display

Excessive paint leakage into throat packing nut

Fluid is spitting from gun

Cause Solution

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.

Service piston ball. See manual 309277.

Replace packings. See manual 309277.

Clean strainer.

Tighten suction tube.

Increase pressure. See operation manual.

Fluid filter or tip is clogged or dirty.

Clean filter and tip. See operation manual or gun manual 311254.

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 manual 309277.

Large pressure drop in hose with heavy materials.

Replace pump packings. See manual 309277.

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.

Bring sprayer to Graco distributor for repair.

Suction tube strainer is clogged.

Suction tube air leak.

Drain line to paint hopper is clogged.

Clean strainer

Tighten suction tube

Clean drain line

Intake valve is leaking.

Pump packings are worn.

Paint is too thick.

Engine speed is too high.

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.

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

Replace pump packings. See manual 309277.

Thin the paint according to supplier recommendations.

Decrease throttle setting before priming pump. 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 manual 309277.

Replace rod. See manual 309277.

Check and tighten all fluid connections. Reprime pump.

See operation manual.

Clear tip. See manual 311254.

Refill fluid supply. Prime pump. See operation manual.

Check fluid supply often to prevent running pump dry.

3A2593A Repair 39

Troubleshooting

Problem

Excessive leakage around hydraulic motor piston rod wiper

Cause

Piston rod seal worn or damaged.

Solution

Replace hydraulic motor piston rod wiper and seal.

Sprayer overheats

Excessive hydraulic pump noise

Display does not turn on

Gallon (liter) counter not adding fluid volume

Distance not adding properly

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

Mils not calculating

Pressure control knob does not rotate

Pressure control knob rotates freely with no pressure change

Gun does not trigger

Gun triggering is slow

Paint buildup on hydraulic components

Hydraulic oil level is low

Low hydraulic fluid level

Pulleys loose on hydraulic pumps

Main power switch is not turned on

Main fuse is blown

Cable between display and board disconnected or damaged

Display board failure

Fluid pressure not high enough

Clean hydraulic components.

Fill with hydraulic oil. See operation manual.

Shut off sprayer. Add fluid*.

Remove belt guard. Check and tighten loose pulley.

Turn main power switch on.

Replace fuse. See Fuse Replacement

, page 28.

Reconnect or replace touch pad.

Broken or disconnected wire

Missing or damaged magnet

Bad sensor

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.

Replace sensor. See Hydraulic Motor Replacement ,

page 18.

Perform calibration procedure. See Operation manual.

Adjust tire pressure to 55 +/- 5 psi (380 +/- 34 kPa).

Machine not calibrated

Rear tire pressure is too low or too high

Gear teeth missing or damaged

(pump side only)

Distance sensor is loose or broken

Distance sensor

Gallon counter

Bad or damaged control board

Replace distance gear/wheel hub.

Knob is jammed

Set screw at hydraulic pump connection is loose

Remote cable is broken or disconnected

Main power 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

Gun cable is disconnected or broken

Gun trigger control switch 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 sensor.

See “Distance not adding properly”.

See “Gallon (liter) counter not adding fluid volume”.

Replace control board.

Pull back cover where remote cable connects to hydraulic pump and turn counter-clockwise (ccw) until free.

Remove cover and tighten set screw.

Reassemble cover.

Replace or reconnect cable.

Turn main power switch ON.

Turn gun selector switch ON.

Increase ground speed to be greater than 0.7 mph

(1.1 kph).

Increase fluid pressure up to at least

1000 psi.

Reconnect or replace cable.

Reconnect or replace gun trigger control switch.

Reconnect or replace wires.

Change gun cable routing or replace cable.

Increase fluid pressure up to at least 1000 psi.

40 3A2593A Repair

Troubleshooting

Problem Cause Solution

AUTO Mode

Line spacing is not accurate

Gun does not trigger

Wrong line pattern loaded

Machine not calibrated

See Gun Does Not Trigger

, page 40.

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)

3A2593A Repair 41

Wiring Diagram

Wiring Diagram

RED BLA RED RED YELL

RED BLA

42 ti19065a

3A2593A Repair

Wiring Diagram

Wiring Parts List

Ref.

Part Description

4 15K357 SENSOR, distance

54 24N501 KIT, repair, engine, GX270

(includes 54a)

54a 24N502 VOTLAGE REGULATOR

57 125877 CLUTCH, electric, LL250

112 119720 SWITCH, reed w/connector

134 24L904 CONTROL, handlebar

150 115753 BATTERY, 33 AH, sealed

187 237686 WIRE, ground assembly w/ clamp

189 16N513 MANIFOLD, hydraulic, two piston

189a 24N577 COIL, solenoid, hydraulic, manifold

(included in 189)

214b 24N565 KIT, repair, control board

214c 24N564 KIT, repair, display board

Qty.

1

1

1

1

1

1

1

1

2

1

1

1

Ref.

Part Description Qty.

214e 16N374 SWITCH, membrane

214f 24N566 KIT, repair, switch board

214h 126078 SWITCH, rocker, dpdt

214t 16P019 HARNESS, switch board

220 16N407 HARNESS, wire, LL250

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 2

1

1

237 126095 HOLDER, fuse

238 126096 FUSE, 30A

253 114956 TERMINAL, wire tap, insulated

391 24N516 KIT, repair, transducer

1

1

1

1

1

1

1

1

1

1

1

3A2593A Repair 43

Hydraulic Diagram

Hydraulic Diagram

44 ti19064a

3A2593A Repair

Hydraulic Diagram

Hydraulic Parts List

Ref.

Part Description Qty.

2

22

63

125929 MOTOR, wheel

16M271 HOSE, coupled, assembly, LL250

247930 KIT, repair, hydraulic pump

108 117328 FITTING, nipple, straight

109 117441 VALVE, ball

110 287175 KIT, repair, hose, hydraulic s

111 287176 KIT, repair, hose, hydraulic r

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

165 16M275 HOSE, coupled, return line, LL250

166 16M276 HOSE, coupled, feed line, LL250

189 16N513 MANIFOLD, hydraulic, two piston

(includes two 189b and two 189c)

189a 24N577 COIL, solenoid, hydraulic, manifold 1

189b 24N490 KIT, repair, solenoid

(includes 189a)

1

189c 24N491 KIT, repair, actuator piston 1

190 124941 FITTING, long elbow, hydraulic 1

191 116829 FITTING, 90 degree, w/adjustable 1

1

1

1

1

2

2

1

1

1

1

1

Ref.

Part Description

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

309 16M160 COVER, reservoir, LL250, painted

320 287179 KIT, repair, pump, 200HS

327 246173 KIT, repair, oil filter

333 120184 FITTING, hydraulic

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

351 16P776 TUBE, supply, hydraulic

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

1

1

1

1

2

1

2

1

1

1

3A2593A Repair 45

Notes

Notes

46 3A2593A Repair

Notes

Notes

3A2593A Repair 47

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.

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.

For patent information, see www.graco.com/patents.

Original instructions.

This manual contains English. MM 3A2593

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441

Copyright 2010, Graco Inc. is registered to ISO 9001 www.graco.com

Revision A - November 2012

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