Graco 3A2593B User Manual

Repair

ti24910a

LineLazer IV 250SPS 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.

Related Manuals:

3A2090 Operation

3A2598 Parts

311254 Gun

309277 Pump

312307 Auto-Layout Applications Methods

3A2593B

Table of Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Component Identification . . . . . . . . . . . . . . . . . . . . 7

Component Identification (Controls) . . . . . . . . . . . 8

Grounding Procedure

(For Flammable Materials Only) . . . . . . . . . . . 9

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 9

Ground Drive Belt Replacement . . . . . . . . . . . . . 10

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

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

Oil Reservoir Belt Replacement . . . . . . . . . . . . . . 11

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Hydraulic System Purging . . . . . . . . . . . . . . . . . . 12

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

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

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

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

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Hydraulic Gun Manifold Replacement . . . . . . . . . 16

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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

Paint Pump Replacement . . . . . . . . . . . . . . . . . . . 18

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

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

Hydraulic Motor Replacement . . . . . . . . . . . . . . . 19

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Clutch Replacement . . . . . . . . . . . . . . . . . . . . . . . 20

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

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

Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . 22

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

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

Touch-Pad Replacement . . . . . . . . . . . . . . . . . . . . 24

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Control Board, Toggle Switches and Display

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 25

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

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

Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . 28

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

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 29

Forward/Reverse Cable Replacement . . . . . . . . . 30

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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

Steering Cable Replacement . . . . . . . . . . . . . . . . 32

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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

Front Wheel Replacement . . . . . . . . . . . . . . . . . . . 34

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

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

Parking Brake Service . . . . . . . . . . . . . . . . . . . . . . 35

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

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

Rear Wheel and Wheel Motors . . . . . . . . . . . . . . . 36

Rear Wheel Removal . . . . . . . . . . . . . . . . . . . . 36

Rear Wheel Installation . . . . . . . . . . . . . . . . . . . 36

Wheel Motor Removal . . . . . . . . . . . . . . . . . . . . 36

Wheel Motor Installation . . . . . . . . . . . . . . . . . . 37

Wheel Sensor Replacement . . . . . . . . . . . . . . . 37

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Wiring Parts List . . . . . . . . . . . . . . . . . . . . . . . . 44

Hydraulic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 45

Hydraulic Parts List . . . . . . . . . . . . . . . . . . . . . . 46

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 49

2 3A2593B Repair

Models

Model Guns Pressurized Bead System Description

24F307 2 No LLIV 250SPS (North America, Latin America, Asia Pacific)

24K960 1 No LLIV 250SPS (Latin America, Asia Pacific)

24K961 1 No LLIV 250SPS (Europe)

24K962 2 No LLIV 250SPS (Europe)

24M608 1 No FieldLazer G400 (North America)

16V470 1 Yes, 1 Tank LLIV 250 SPS (Latin America, Asia Pacific)

16V471 1 Yes, 1 Tank LLIV 250 SPS (Europe)

16V473 2 Yes, 1 Tank LLIV 250 SPS (North America, Latin America, Asia Pacific)

16V474 2 Yes, 1 Tank LLIV 250 SPS (Europe)

24U561 2 Yes, 2 Tanks LLIV 250 SPS (North America, Latin America, Asia Pacific)

Models

3A2593B Repair 3

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 anti-

static 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 servic-

ing 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.

4 3A2593B Repair

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 Pres-

sure 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 compo-

nent. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equip-

ment 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 manufac-

turer’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.

3A2593B Repair 5

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.

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.

6 3A2593B Repair

Component Identification

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13.

11.

12.

10.

OFF

16.1.

14.

15.

17.

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Component Identification

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

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

9 Straight Line Adjuster

3A2593B Repair 7

Component Identification (Controls)

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3.4.

11.

10.

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Component Identification (Controls)

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

8 3A2593B Repair

Grounding Procedure (For Flammable Materials Only)

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PAINT

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Grounding Procedure

(For Flammable Materials Only)

This equipment must be grounded to reduce the risk of static sparking. Static sparking can cause fumes to ignite or explode. Grounding provides an escape wire for the electric current.

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).

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

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.

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

4. Engage gun trigger safety. Turn prime valve down.

3A2593B Repair 9

Ground Drive Belt Replacement

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Ground Drive Belt Replacement

Removal

1. Loosen four screws and remove belt cover.

2. Loosen two hold-down bolts.

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

Installation

1. Install belt onto pulleys.

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

Ground Drive Belt

Tension Recommendations

New Belt

Used Belt

Gates Sonic Tension Meter Settings: M = MASS = 85 g/m

3. Install mounting plate and tighten two hold-down bolts.

Tension 53 +/- 2 Lbf (236 +/- 9 N) Frequency 167 +/- 3 Hz Tension 45 +/- 2 Lbf (200 +/- 9 N) Frequency 155 +/- 3 Hz

W = # of belts = 1 S = Span = 157 mm

4. Remove belt.

10 3A2593B Repair

4. Replace belt cover and tighten four screws.

Oil Reservoir Belt Replacement

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Oil Reservoir Belt Replacement

Removal

NOTE: Ground drive belt must be removed before oil

reservoir belt can be replaced (see page 10).

1. Loosen four hold-down bolts.

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

Installation

1. Replace belt.

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

Oil Reservoir Belt

Tension Recommendations

New Belt

Used Belt

Gates Sonic Tension Meter Settings: M = MASS = 85 g/m

Tension 55 +/- 2 Lbf (245 +/- 9 N) Frequency 114 +/- 2 Hz Tension 48 +/- 2 Lbf (214 +/- 9 N) Frequency 106 +/- 2 Hz

W = # of belts = 1 S = Span = 236 mm

3. Remove belt.

3A2593B Repair 11

3. Tighten four hold-down bolts.

4. Install Ground Drive Belt and tighten to proper tension (see page 10).

Hydraulic System Purging

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Full Range (cold)

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Full Range (cold)

Hydraulic System Purging

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.

5. Turn on the Main Power Switch to engage clutch.

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

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.

2. Fill oil reservoir to “Full” range.

3. Make sure drive wheel release is closed (+).

4. Start engine and run at low speed.

12 3A2593B Repair

7. Turn the prime valve down and open the hydraulic pump valve. Allow the paint pump to stroke 10 times and then close the hydraulic pump valve.

8. The hydraulic gun manifold is self-purging.

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

Ground Drive Pump Replacement

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Ground Drive Pump Replacement

Removal

1. Remove Ground Drive Belt, page 10.

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

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

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

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

Installation

1. Insert pump (63) into bracket (62) and install two mounting bolts (82) and washers (55).

2. Install tie rod (40) with nut (3) to lever underneath pump (63).

3. Connect all fittings and hoses to pump (63).

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

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

6. Install Ground Drive Belt and tighten to proper tension (see page 10).

4. Disconnect all fittings and hoses from pump (63).

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

7. Purge Hydraulic System, page 12.

3A2593B Repair 13

Oil Reservoir Pump Replacement

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Oil Reservoir Pump Replacement

Removal

1. Remove belt cover and Oil Reservoir Belt, page

11.

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

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

Installation

1. Install pump onto oil reservoir cover with four screws.

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

4. Remove set screw and cable.

5. Remove eight screws and oil reservoir cover with pump.

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.

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

14 3A2593B Repair

Oil Reservoir Pump Replacement

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4. Turn pressure control knob clockwise until seated.

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

7. Slide cable sleeve up and tighten screw.

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

6. Install cable and tighten set screws.

9. Install and tension Oil Reservoir Belt (page 11) and Ground Drive Belt (page 10).

10. Purge hydraulic system, page 12.

3A2593B Repair 15

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