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
EN
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
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
ti15841a
13.
8.
11.
3.
12.
10.
OFF
ON
2.
6.
9.
4.
16.1.
14.
7.
5.
15.
17.
ti24911a
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)
2.
1.
on
off
5.
6.
9.
3.4.
11.
1
2
7.
1
2
8.
10.
ti18719a
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)
ti6740a
PAINT
ti3305a
ti3441a
ti3324a
ti6473a
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.
ti3306a
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
ti19128a
ti19130a
ti19131a
ti19133a
ti19134a
ti19132a
ti19129a
ti19128a
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
ti19147a
ti19146a
ti19148a
ti19149a
ti19150a
ti19151a
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
ti18587a
Full Range (cold)
+
ti18576a
ti18562a
ti18552a
ti18718a
ti6473a
on
off
ti19669a
Full Range (cold)
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 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.
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
63
71
71
64
82
ti19135a
55
40
3
62
60
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 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
ti19139a
ti24913a
ti19144a
ti19142a
ti24914a
ti19672a
ti19671a
ti24914a
ti19670a
Oil Reservoir 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 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
ti19143a
ti19145a
ti19139a
ti24913a
ti23905a
ti23906a
ti23906a
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
Hydraulic Gun Manifold Replacement
ti24196a
ti24916a
ti19163a
ti19164a
ti19161a
Gun 2
Gun 1
ti19159a
Gun #
ti19667a
ti19160a
Hydraulic Gun Manifold
Replacement
Removal
1. Remove tank lid and siphon tube.
2. Remove tank from unit.
6. Label wire harnesses GUN 1 and GUN 2. Disconnect two wire harnesses from solenoids.
7. Label gun cables Gun 1 and Gun 2. Disconnect gun
cables from actuators.
8. Use a needle-nose pliers to remove gun cables from
bracket.
3. Remove six screws from front shield.
4. Remove front shield from unit.
5. Loosen four screws and remove pad.
9. Use wrench to disconnect manifold tubes by the
paint pump. NOTE: Oil will spill. Use a rag to con-
tain the oil.
16 3A2593B Repair
Hydraulic Gun Manifold Replacement
ti19162a
ti19162a
ti19160a
ti19159a
ti19161a
Gun 2
Gun 1
10. Disconnect manifold tubes at manifold.
11. Remove two mounting bolts and slide hydraulic
manifold down and out from unit.
Installation
1. Slide hydraulic manifold in and up into unit. Install
and tighten two mounting bolts.
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.
6. Connect two wire harnesses to solenoids.
NOTE: Be sure to connect Gun 1 to coil closest to
center of sprayer.
2. Loosely install manifold tubes to manifold.
3. Loosely install manifold tubes by the paint pump.
Tighten four nuts.
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.
3A2593B Repair 17
Paint Pump Replacement
115
114
107
106
123
ti19138a
116
95
120
105
104
109
197
110
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 9.
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).
18 3A2593B Repair
Hydraulic Motor Replacement
111
112
113
193
ti19688a
116
110
109
108
196
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 9.
2. Remove Paint Pump, page 18.
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 18.
6. Purge hydraulic system, page 12.
3A2593B Repair 19
Clutch Replacement
ti19215a
ti19131a
ti19213a
ti19216a
81
61
ti19697a
ti19696a
ti19214a
56
60
58
59
57
ti19212a
Clutch Replacement
Removal
1. Remove Ground Drive Belt, page 10.
2. Remove Oil Reservoir Belt, page 11.
3. Remove two hold-down bolts for the ground drive
pump bracket.
4. Unscrew tensioning bolt from the ground drive
pump bracket.
7. Remove engine recoil starter and place a screwdriver through the recoil starter cup.
5. Move ground drive pump assembly aside.
6. Remove three bolts (81) and pulley (61).
8. Remove center bolt (59) and remove clutch (57).
9. Disconnect clutch connector to main wire harness.
20 3A2593B Repair
Clutch Replacement
ti19214a
56
60
58
59
57
ti19211a
ti19692a
59
58
ti19216a
81
61
ti19704a
ti19212a
ti19908a
Installation
1. Install spacer (56) and key (60) onto crankshaft.
Slide clutch (57) onto crankshaft.
2. Align clutch and wire in bracket.
4. Install pulley (61) and torque three screws (81) to 10
ft-lb (13 N•m).
5. Install recoil starter onto engine.
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.
6. Connect clutch to wire harness.
7. Install ground drive pump assembly with tensioning
and two hold-down bolts.
8. Install and tension Oil Reservoir Belt (page 11)
and Ground Drive Belt (page 10).
3A2593B Repair 21
Engine Replacement
ti15307a
ti19186a
ti19183a
ti19185a
ti19188a
ti19187a
ti19703a
Engine Replacement
Removal
1. Remove Clutch, see page 20.
2. Disconnect all wires from engine.
3. Remove air filter cover, element and base.
5. Disconnect choke cable.
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.
8. Pull rope through rope guide.
4. Disconnect throttle cable.
9. Remove four mounting bolts from engine.
10. Remove engine. NOTE: Engine voltage regulator is
located below engine mounting plate. Remove two
screws and disconnect wires.
22 3A2593B Repair
Engine Replacement
ti19706a
ti19187a
ti19708a
ti20066a
1 in. (25 mm)
ti19686a
ti19690a
ti19186a
ti19668a
Installation
1. Install engine voltage regulator below engine
mounting plate with two screws. Connect regulator
to wire harness.
2. Install engine and tighten four mounting bolts and
nuts.
d. Tighten screw on hex-shaped pivot.
e. Verify proper operation of engine choke.
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.
3. Use compressed air to feed recoil starter rope
through rope guide.
4. Feed rope through recoil starter handle and tie knot.
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.
7. Install air filter base, element and cover.
8. Connect three wires to engine.
9. Install Clutch, see page 20.
10. Add gas and oil to engine (see Operation manual).
11. Start engine and verify high speed of 3600 rpm.
3A2593B Repair 23
Touch-Pad Replacement
ti19098a
ti19910a
ti19910a
ti19098a
Touch-Pad Replacement
Removal
1. Remove six screws and control shroud.
2. Disconnect ribbon cable from touch-pad at display
board.
Installation
1. Apply touch-pad to sheet metal.
2. Connect ribbon cable from touch-pad at display
board.
3. Install control shroud with six screws.
3. Peel off touch-pad and remove adhesive from sheet
metal.
24 3A2593B Repair
Control Board, Toggle Switches and Display Replacement
ti24916a
ti24916a
ti19163a
ti19164a
ti19098a
ti19701a
ti19702a
ti20244a
Control Board, Toggle
Switches and Display
Replacement
Removal
1. Remove Fuse to disconnect battery, page 29.
2. Remove tank lid and siphon tube.
7. Remove six screws and control shroud.
8. Remove two screws and splash shield.
3. Remove tank from unit.
4. Use wrench to remove six screws from front shield.
5. Remove front shield from unit.
6. Remove four screws and remove pad.
9. Remove two toggle switch nuts from control panel.
10. Feed toggle switches through control panel.
3A2593B Repair 25
Control Board, Toggle Switches and Display Replacement
ti20135a
ti20133a
ti20136a
ti20133a
ti20132a
ti19910a
ti20245a
ti19199a
ti19198a
ti19199a
ti19198a
11. If replacing the toggle switches loosen two screws
holding the ferrite core. Disconnect cable and
remove toggle switch board.
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.
13. If replacing control board, disconnect all wires from
control board. Remove eight mounting screws and
remove control board.
Installation
1. If replacing control board, install control board with
eight mounting screws.
2. Connect all wires to control board. See Wiring
Diagram, page 43.
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
26 3A2593B Repair
cable to toggle switch board.
Control Board, Toggle Switches and Display Replacement
ti19691a
ti19705a
ti19098a
ti19171a
ti19200a
ti24917a
ti24917a
5. Feed toggle switches through control panel and
install two toggle switch nuts.
6. Install Fuse, see page 29. Check control, switches
and display.
7. Install splash shield with two screws.
8. Install control shroud with six screws.
10. Install front shield and tighten six screws.
11. Install tank, lid and siphon tube.
9. Install pad and tighten four screws.
12. If control board was replaced, calibrate distance
sensor (see Operation manual).
3A2593B Repair 27
Battery Replacement
ti24916a
ti19163a
ti24918a
ti24919a
ti24919a
ti24920a
ti24921a
ti19200a
ti24917a
ti24917a
Battery Replacement
Removal
1. Remove tank lid and siphon tube.
2. Remove tank from unit.
3. Use wrench to remove six screws from front shield.
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.
3. Install battery hold down strap.
4. Remove front shield from unit.
5. Remove hold down strap from battery.
NOTICE
To reduce the risk of shorting the battery, always disconnect NEGATIVE (black wire) first.
6. Disconnect two wires from battery.
4. Install front shield and use wrench to tighten six
screws into shield.
5. Replace tank and install lid with siphon tube.
7. Remove battery.
28 3A2593B Repair
Fuse Replacement
ti19209a
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.
3A2593B Repair 29
Forward/Reverse Cable Replacement
ti24916a
ti24916a
ti19163a
ti19128a
ti19699a
40
3
148
ti19700a
62
40
3
148
Forward/Reverse Cable
Replacement
Removal
1. Remove tank lid and siphon tube.
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.
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).
2. Remove tank from unit.
3. Use wrench to remove six screws from front shield.
4. Remove front shield from unit.
5. Loosen four screws and remove belt cover.
8. Install new cable (148) as old cable is removed to
follow same route through frame.
30 3A2593B Repair
Forward/Reverse Cable Replacement
ti19700a
62
40
3
148
ti19699a
40
3
148
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).
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.
3A2593B Repair 31
Steering Cable Replacement
ti24916a
ti24916a
ti19163a
ti19164a
ti19098a
ti18550a
ti19695a
40
48
3
ti19698a
3
40
48
Steering Cable
Replacement
Removal
1. Remove tank lid and siphon tube.
2. Remove tank from unit.
3. Use wrench to remove six screws from front shield.
7. Apply parking brake. Raise front wheel off the
ground and support frame on two jack stands.
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.
4. Remove front shield from unit.
5. Loosen four screws and remove pad.
6. Remove six screws and control shroud.
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.
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.
32 3A2593B Repair
Steering Cable Replacement
ti19685a
Adjust to match
other side
of front fork
ti19698a
3
40
48
ti19685a
Adjust to match
other side
of handlebar
ti19695a
40
48
3
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.
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).
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).
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).
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.
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.
3A2593B Repair 33
Front Wheel Replacement
ti19693a
34
35
37
36
36
39
ti20125a
34
35
37
36
36
39
ti20125a
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).
2. Remove locknut (39) from axle bolt (37) and remove
axle bolt (37) from fork (34).
3. Remove two spacers (36) and wheel (35) from fork
(34).
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).
34 3A2593B Repair
Parking Brake Service
16
17
1313
A
B
15
14
10
AA
ti19684a
A
A
14
A
15
B
13
16
10
17
16
17
1313
A
B
15
14
10
AA
ti19684a
A
A
14
A
15
B
13
16
10
17
Parking Brake Service
Installation
1. Install lever (14) with pin (B) and clip (13).
Removal
1. Remove tire, wheel hub, and fender. See Wheel
Motor Removal, page 36.
2. Remove clips (13) from three pins (A). Remove pins
and levers.
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 Installation, page 37.
3. Use screwdriver to remove spring (15). Remove clip
(13) and pin (B).
5. Adjust screw (17) to hold tire when brake lever (16)
is depressed.
4. Replace damaged or worn parts.
3A2593B Repair 35
Rear Wheel and Wheel Motors
ti18587a
ti18589a
22
16
ti18588a
ti18589a
22
16
22b
78
21a
79
112
21b
ti18584a
56
19
6
5
4
Rear Wheel and Wheel Motors
Wheel Motor Removal
1. Place jack under frame near wheel and raise jack.
Rear Wheel Removal
1. Set LineStriper on blocks so wheels are off ground.
2. Remove four lug nuts (22) and wheel (16).
2. Remove four lug nuts (22) and wheel (16).
3. Remove pin (56), castle nut (21b) and wheel hub
(22b). Wheel hub may require a wheel puller; not
supplied by Graco.
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.
3. Inflate rear tires to 55 +/- 5 psi (380 +/- 34 kPa).
36 3A2593B Repair
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.
Rear Wheel and Wheel Motors
22b
78
21a
79
112
21b
ti18584a
56
19
6
5
4
ti18589a
22
16
ti24916a
ti19163a
ti18589a
22
16
ti19328a
ti19099a
4
5
6
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).
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).
2. Remove tank from unit.
3. Use wrench to remove six screws from front shield
and remove front shield from unit.
4. Place jack under frame near pump-side wheel and
raise jack.
5. Remove four lug nuts (22) and wheel (16).
5. Install wheel (16) and four lug nuts (22). Alternately
tighten lug nuts opposite each other.
6. Purge hydraulic system. See Hydraulic System
Purging, page 12.
Wheel Sensor Replacement
Removal
1. Remove tank lid and siphon tube.
6. Disconnect wheel sensor connector from wire harness.
7. Use wrench to remove screw (6), clamp (5), and
wheel sensor (4).
3A2593B Repair 37
Rear Wheel and Wheel Motors
ti19099a
4
5
6
ti19328a
ti19329a
ti18564a
ti18589a
22
16
ti19200a
ti24917a
Installation
1. Install wheel sensor (4) and clamp (5) with screw
(6).
2. Connect wheel sensor connector to wire harness.
5. Install wheel (16) and four lug nuts (22).
6. Lower jack.
7. Install front shield with six screws.
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.
NOTE: Sensor is working properly if the measure
display reads 12.3 to 12.7 ft (3.75 to 3.87 m).
8. Install tank and siphon tube.
9. Calibrate sprayer. See operation manual.
38 3A2593B Repair
Troubleshooting
General
Problem Cause Solution
Troubleshooting
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
Excessive hydraulic load. Main power switch
is on.
Engine is out of gas. Refill gas tank. See engine manual.
Fuel shut-off lever is OFF. Move fuel shut-off lever to ON position.
Engine switch is OFF. Turn engine switch ON.
Engine oil level is low.
Engine is cold. Use engine choke.
Spark plug cable is disconnected or damaged. Connect spark plug cable or replace spark plug cable.
Main power switch is stuck in engine stop
position.
Oil is seeping into combustion chamber.
Improperly adjusted high speed setting. Reset high speed to 3600 - 3700 engine rpm at no load.
Worn engine governor. Adjust or replace engine governor.
Main power switch is not turned ON. Turn main power switch ON.
Hydrostatic drive is not engaged. Close wheel motor bypass valve to engage drive.
Drive cable is disconnected or broken. Reconnect or replace cable.
Clutch wire harness is disconnected or broken.
Clutch does not work. Replace clutch.
Ground drive belt is worn or broken. Adjust or replace ground drive belt.
Ground Drive Pump is worn or not working. Replace ground drive pump.
Wheel motor(s) worn or not working. Replace wheel motor.
Main power switch is OFF. Turn main power switch ON.
Pump valve is OFF. Turn pump valve ON.
Pressure setting is too low.
Prime/drain valve is closed and system
is pressurized.
Hydraulic fluid too low. Shut off sprayer. Add fluid*.
Oil reservoir belt is worn, broken, or off
the pulley.
Tip is clogged. Reverse tip to clean. See manual 311254.
Displacement pump piston rod is stuck due to
dried paint.
Hydraulic motor not shifting.
Turn main power switch OFF.
Check oil level and add oil if necessary. See engine
manual.
Replace main power switch.
Remove spark plug. Pull starter 2 to 4 times. Clean or
replace spark plug. Start engine. Keep sprayer upright
to avoid oil seepage.
Reconnect or replace harness as
necessary.
Turn pressure adjusting knob clockwise to increase
pressure. See operation manual.
Open prime/drain valve.
Replace oil reservoir belt. See page 11.
Repair pump. See manual 309277.
Set pump valve OFF. Turn pressure down. Turn engine
OFF. Pry rod up or down until hydraulic motor shifts.
3A2593B Repair 39
Troubleshooting
Problem Cause Solution
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
Piston ball is not seating. Service piston ball. See manual 309277.
Piston packings are worn or damaged. Replace packings. See manual 309277.
Suction tube strainer is clogged. Clean strainer.
Suction tube air leak. Tighten suction tube.
Pressure setting is too low. Increase pressure. See operation manual.
Fluid filter or tip is clogged or dirty.
Clean filter and tip. See operation manual or gun
manual 311254.
Engine speed is too low. Increase throttle setting. See operation manual.
Intake valve ball is packed with material or is
not seating properly.
Clean intake valve. See manual 309277.
Pump packings are worn or damaged. Replace pump packings. See manual 309277.
Use larger diameter hose and/or reduce overall length
Large pressure drop in hose with heavy
materials.
of hose. Use of more than 100 ft x 1/4 in. hose signifi-
cantly reduces performance of sprayer. Use 3/8 in.
hose for optimum performance.
Oil reservoir hydraulic filter is dirty or clogged. Change hydraulic filter and hydraulic oil.
Intake line to pump inlet is not tight. Tighten intake line to pump inlet.
Hydraulic motor is worn or damaged. Bring sprayer to Graco distributor for repair.
Suction tube strainer is clogged. Clean strainer
Suction tube air leak. Tighten suction tube
Drain line to paint hopper is clogged. Clean drain line
Intake valve is leaking.
Clean intake valve. Be sure ball seat is not nicked or
worn and that ball seats well. Reassemble valve.
Pump packings are worn. Replace pump packings. See manual 309277.
Paint is too thick. Thin the paint according to supplier recommendations.
Engine speed is too high.
New pump or new packings
Decrease throttle setting before priming pump. See
operation manual.
Pump break-in period takes up to 100 gallons
of material.
Faulty transducer Replace transducer.
Throat packing nut is loose.
Remove throat packing nut spacer. Tighten throat
packing nut just enough to stop leakage.
Throat packings are worn or damaged. Replace packings. See manual 309277.
Displacement rod is worn or damaged. Replace rod. See manual 309277.
Air in pump or hose
Check and tighten all fluid connections. Reprime pump.
See operation manual.
Tip is partially clogged. Clear tip. See manual 311254.
Fluid supply is low or empty.
Refill fluid supply. Prime pump. See operation manual.
Check fluid supply often to prevent running pump dry.
40 3A2593B Repair
Problem Cause Solution
Troubleshooting
Excessive leakage around hydraulic
motor piston rod wiper
Sprayer overheats
Excessive hydraulic pump noise
Piston rod seal worn or damaged. Replace hydraulic motor piston rod wiper and seal.
Paint buildup on hydraulic components Clean hydraulic components.
Hydraulic oil level is low Fill with hydraulic oil. See operation manual.
Low hydraulic fluid level Shut off sprayer. Add fluid*.
Pulleys loose on hydraulic pumps Remove belt guard. Check and tighten loose pulley.
Main power switch is not turned on Turn main power switch on.
Main fuse is blown Replace fuse. See Fuse Replacement, page 29.
Display does not turn on
Cable between display and board disconnected
or damaged
Display board failure Replace display board.
Fluid pressure not high enough Must be over 800 psi (55 bar) for counter to add.
Gallon (liter) counter not
adding fluid volume
Broken or disconnected wire
Missing or damaged magnet Reposition or replace magnet.
Bad sensor
Machine not calibrated Perform calibration procedure. See Operation manual.
Distance not adding properly
(MEASURE mode will be inaccurate
and speed will be wrong)
Rear tire pressure is too low or too high Adjust tire pressure to 55 +/- 5 psi (380 +/- 34 kPa).
Gear teeth missing or damaged
(pump side only)
Distance sensor is loose or broken Reconnect or replace sensor.
Distance sensor See “Distance not adding properly”.
Mils not calculating
Gallon counter See “Gallon (liter) counter not adding fluid volume”.
Bad or damaged control board Replace control 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 Replace or reconnect cable.
Main power switch is not turned ON Turn main power switch ON.
Gun selector switch is OFF Turn gun selector switch ON.
Display is in AUTO MODE and speed is less
than 0.7 mph (1.1 kph)
Gun does not trigger
System pressure is too low
Gun cable is disconnected or broken Reconnect or replace cable.
Gun trigger control switch is disconnected or
broken
Disconnected or broken wires from control
board to solenoid
Gun triggering is slow
Gun cable is pinched or kinked Change gun cable routing or replace cable.
System pressure is too low Increase fluid pressure up to at least 1000 psi.
Reconnect or replace touch pad.
Check wires and connections. Replace any broken
wires.
Replace sensor. See Hydraulic Motor Replacement,
page 19.
Replace distance gear/wheel hub.
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.
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 gun trigger control switch.
Reconnect or replace wires.
3A2593B Repair 41
Troubleshooting
Problem Cause Solution
AUTO Mode
Line spacing is not accurate
Gun does not trigger See Gun Does Not Trigger, page 41.
Wrong line pattern loaded Reload the correct pattern.
Machine not calibrated Perform calibration routine (see Operation manual).
PARKING LAYOUT Mode
Gun selector switch is OFF Turn gun selector switch ON.
Gun does not apply dots
* Use only Graco approved hydraulic fluid 169236 (5 gallons / 18.9 liter) or 207428 (1 gallon / 3.8 liter)
Dot size setting is too small Increase dot size.
Pressure is too low Increase pressure to 1000 psi.
42 3A2593B Repair
Wiring Diagram
TO ENGINE
YELLOW
RED
BLACK
TO GROUND LUG
TO GROUND LUG
TO GROUND LUG
GUN 2
GUN 1
TO GROUND LUG
WHITE
RED
RED
BLACK
BLACK
RED
BLACK
RED
BLACK
RED
RED
YELLOW
BLACK
YELLOW
WHITE
BLACK
RED
BLACK
214e
214c
391
224
225
189
4
112
223
187
238 237 221
150
222
253
54a
57
220
214h
214t
214f
214b
134
54
ti19065a
Wiring Diagram
189a
3A2593B Repair 43
Wiring Diagram
Wiring Parts List
Qty
Ref. Part Description
4 15K357 SENSOR, distance 1
54 24N501 KIT, repair, engine, GX270
(includes 54a)
54a 24N502 VOTLAGE REGULATOR 1
57 125877 CLUTCH, electric, LL250 1
112 119720 SWITCH, reed w/connector 1
134 24L904 CONTROL, handlebar 1
150 115753 BATTERY, 33 AH, sealed 1
187 237686 WIRE, ground assembly w/ clamp 1
189 16N513 MANIFOLD, hydraulic, two piston 1
189a 24N577 COIL, solenoid, hydraulic, manifold
(included in 189)
214b 24N565 KIT, repair, control board 1
214c 24N564 KIT, repair, display board 1
Ref. Part Description
.
214e 16N374 SWITCH, membrane 1
214f 24N566 KIT, repair, switch board 1
1
214h 126078 SWITCH, rocker, dpdt 1
214t 16P019 HARNESS, switch board 1
220 16N407 HARNESS, wire, LL250 1
221 16N542 WIRE, positive battery 1
222 16N541 WIRE, negative battery 1
223 16N540 HARNESS, light connection 1
224 16N539 HARNESS, sensor adapter 1
225 16N543 HARNESS, wire, hydraulic actuator 2
237 126095 HOLDER, fuse 1
2
238 126096 FUSE, 30A 1
253 114956 TERMINAL, wire tap, insulated 1
391 24N516 KIT, repair, transducer 1
Qty
.
44 3A2593B Repair
Hydraulic Diagram
196
189
2
2
22
63
191
166
166
3XX
327
110
111
366
108
109
198
197
190
333
3XX
193
194
189C
371
189A
189B
3YY
370
366
372
309
320
ti24923a
Hydraulic Diagram
3A2593B Repair 45
Hydraulic Diagram
Hydraulic Parts List
Qty
Ref. Part Description
2 125929 MOTOR, wheel 2
22 16M271 HOSE, coupled, assembly, LL250 2
63 247930 KIT, repair, hydraulic pump 1
108 117328 FITTING, nipple, straight 1
109 117441 VALVE, ball 1
110 287175 KIT, repair, hose, hydraulic s 1
111 287176 KIT, repair, hose, hydraulic r 1
166 16M276 HOSE, coupled, feed line, LL250 2
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)
189c 24N491 KIT, repair, actuator piston 1
190 124941 FITTING, long elbow, hydraulic 1
191 116829 FITTING, 90 degree, w/adjustable 1
193 24M625 TUBE, supply, hydraulic 1
Ref. Part Description
.
194 24M626 TUBE, supply, hydraulic 1
196 126082 FITTING, tee, #8 x #8 x #6 JIC 1
197 126080 FITTING, tee, street 1
198 126081 FITTING, nipple, 3/8-18 x #6 JIC 1
309 16M160 COVER, reservoir, LL250, painted 1
320 287179 KIT, repair, pump, 200HS 1
327 246173 KIT, repair, oil filter 1
333 122970 FITTING, hydraulic 1
350 116829 FITTING, 90 degree, w/adjustable
1
o-ring
351 16P776 TUBE, supply, hydraulic 1
366 117607 FITTING, elbow std thd 2
1
370 100139 PLUG, pipe 1
371 15F519 TUBE, hydraulic, supply 1
372 119841 FITTING, tee, branch 1
Qty
.
2
46 3A2593B Repair
Notes
Notes
3A2593B 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.
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.
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 B, November 2014
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