Graco 3A2593B User's Manual
Contents
1. 223 3A2593B Repair x Wiring Diagram Wiring Parts List Ref 4 54 54a 57 112 134 150 187 189 Part 15K357 24N501 24N502 125877 119720 241904 115753 23 686 16N513 189 24N577 214b 24N565 214c 24N564 44 Description SENSOR distance KIT repair engine GX270 includes 54a VOTLAGE REGULATOR CLUTCH electric LL250 SWITCH reed w connector CONTROL handlebar BATTERY 33 AH sealed WIRE ground assembly w clamp MANIFOLD hydraulic two piston COIL solenoid hydraulic manifold included in 189 KIT repair control board KIT repair display board Qty N a aaa aaa h Ref 214e 214f 214h 214t 220 221 222 223 224 225 237 238 253 391 Part 16N374 24N566 126078 16P019 16N407 16N542 16N541 16N540 16N539 16N543 126095 126096 114956 24N516 Description SWITCH membrane KIT repair switch board SWITCH rocker dpdt HARNESS switch board HARNESS wire LL250 WIRE positive battery WIRE negative battery HARNESS light connection HARNESS sensor adapter HARNESS wire hydraulic actuator HOLDER fuse FUSE 30A TERMINAL wire tap insulated KIT repair transducer Qty h st st N S SS Ss eS eS do do do kh 3A2593B Repair Hydraulic Diagram Hydraulic Diagram A gt2. cd ti19708a 4 Feed rope through recoil starter handle and tie knot 1 in 25 mm a ti20066a 5 Install choke cable ti19668a a Make sure choke knob is pressed down 9 Install Clutch see page 20 b Insert choke cable wire into hex shaped pivot 10 Add gas and oil to engine see Operation manual c Insert cable sheathing under cable clamp and 11 Start engine and verify high speed of 3600 rom tighten screw g y hign sp p 3A2593B Repair 23 Touch Pad Replacement Touch Pad Replacement Removal 1 Remove six screws and control shroud BAT NY es ti19098a 2 Disconnect ribbon cable from touch pad at display board t119910a 3 Peel off touch pad and remove adhesive from sheet metal 24 Installation bh board Apply touch pad to sheet metal Connect ribbon cable from touch pad at display t119910a 3 Install control shroud with six screws t119098a 3A2593B Repair Control Board Toggle Switches and Display Replacement Removal 1 Remove Fuse to disconnect battery page 29 2 Remove tank lid and siphon tube CE tpagiga 3 Remove tank from unit 4 Use wrench to remove six screws from front shield ti19163a 5 Remove front shield from unit 6 Remove four screws and remove pad Sl Ps t119164a 3A2593B Repair Control Board Toggle Switches and Display Replac
3. EU 7 5 A SV LJ Ass Rp K TK Di LO j QS A 3A2593B Repair 21 Engine Replacement Engine Replacement 5 Disconnect choke cable A Ma s Removal 1 Remove Clutch see page 20 2 Disconnect all wires from engine 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 t119188a 8 Pull rope through rope guide 9 Remove four mounting bolts from engine TIA oie 10 Remove engine NOTE Engine voltage regulator is located below engine mounting plate Remove two 4 Disconnect throttle cable screws and disconnect wires t119183a t119703a 22 3A2593B Repair Engine Replacement Installation d Tighten screw on hex shaped pivot e Verify proper operation of engine choke 1 Install engine voltage regulator below engine mounting plate with two screws Connect regulator to wire harness 6 Install throttle cable a Place speed lever to high speed T ti19706a b Insert Z bend wire into hole furthest from pivot 2 Install engine and tighten four mounting bolts and c Place cable sheathing under clamp and pull nuts 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. 3A2593B Repair 41 Troubleshooting IN Son AUTO Mode ue Wrong line pattern loaded Reload the correct pattern Line spacing is not accurate PARKING LAYOUT Mode Use only Graco approved hydraulic fluid 169236 5 gallons 18 9 liter or 207428 1 gallon 3 8 liter 42 3A2593B Repair Wiring Diagram Wiring Diagram TO ENGINE a TO GROUND LUG IS t119065a 150 TO GROUND LUG 214e 221 fm 225 E ES I I 224 GUN 2 GUN 1 O sao TO GROUND LUG E 1 ES _ 237 BLACK S lt Q ANNAN TN AN AM RED SAN Lo AN AN NWN WE E N y See D 238
5. De E E o do qui S _ es i ONO LLL cce OLL N Mm gt gt m goe 45 3A2593B Repair Hydraulic Diagram Hydraulic Parts List Ref 2 22 63 108 109 110 111 166 189 189a 189b 189c 190 191 193 46 Part 125929 16M271 247930 117328 117441 28 7175 287176 16M276 16N513 24N577 24N490 24N491 124941 116829 24M625 Description MOTOR wheel HOSE coupled assembly LL250 KIT repair hydraulic pump FITTING nipple straight VALVE ball KIT repair hose hydraulic s KIT repair hose hydraulic r HOSE coupled feed line LL250 MANIFOLD hydraulic two piston includes two 189b and two 189c COIL solenoid hydraulic manifold KIT repair solenoid includes 189a KIT repair actuator p
6. 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 N INJECTION HAZARD Exhaust contains poisonous carbon monoxide which is colorless and odorless Breathing carbon monoxide can cause death e Do not operate in an enclosed area 4 3A2593B Repair Warnings PRESSURIZED ALUMINUM PARTS HAZARD Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reac tion and equipment rupture Failure to follow this warning can result in death serious injury or property dam age e Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents e 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 e Keep clear of moving parts e Do not operate equipment with protective guards or covers removed e Do not wear loose clothing jewelry or long hair while operating equipment e 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 o
7. is depressed 35 Rear Wheel and Wheel Motors Rear Wheel and Wheel Motors A Ma s Rear Wheel Removal 1 Set LineStriper on blocks so wheels are off ground YU ie a had YU oo O els loeo d e o ollo 6 o allo O 200 O o olle o o o ollo o J ad o D 000 5 FO o ollo o 0o 0o ollo o F o 6 6 6 1 os ooo iF E O O j m E S im Ci HH ta f as t118587a 2 Remove four lug nuts 22 and wheel 16 t118589a 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 t118588a 3 Inflate rear tires to 55 5 psi 380 34 kPa 36 Wheel Motor Removal 1 2 3 4 Place jack under frame near wheel and raise jack Remove four lug nuts 22 and wheel 16 t118589a Remove pin 56 castle nut 21b and wheel hub 22b Wheel hub may require a wheel puller not supplied by Graco ti18584a Remove four bolts 78 lock nuts 79 and fender 19 Remove screw 6 and distance sensor 4 with clamp 5 Disconnect two hydraulic hoses 112 from wheel motor 21a and remove wheel m
8. Install new cable 148 as old cable is removed to follow same route through frame 3A2593B Repair Installation 1 Install new cable 148 by following same route as old cable is being removed 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 3A2593B Repair Forward Reverse Cable Replacement 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 3 148 ti19699a Verify that the handlebar forward reverse lever does NOT touch handlebar grips Adjust cable and ball joints if needed Install belt cover and tighten four screws Install front shield onto unit Use wrench to tighten six screws into front shield Install tank onto unit Install siphon tube and tank lid 31 Steering Cable Replacement Steering Cable Replacement AY Removal 1 Remove tank lid and siphon tube ee Pp ti24916a e J ti24916a 2 2 Remove tank from unit 3 Use wrench to remove six screws from front shield t119163a 4 Remove front shield from unit 5 Loosen four screws and remove pad t119098a 32 N 10 Apply parking brake Raise front wheel off the ground and support
9. ek ARE 18 Hydraulic Motor Replacement 19 Removal avia a lis dls 19 Installation o o ooooooooooooo 19 Clutch Replacement 0 0occococo oo 20 REMOVA vs tada rara aa 20 Installation lt a and See ae ee 21 Engine Replacement 0 o ooocooooo oo 22 Removal uni nato nares o led 22 InStaltalO ia AAA 23 2 Touch Pad Replacement 24 REMOVA train y e A 24 NSTalatO Massiel is 24 Control Board Toggle Switches and Display Replacement 0000 cece eee eee 25 Removal viaria se aed Bes 25 IISTAN ATION dd ai dl aw A ok dd a 26 Battery Replacement ooooooooo 28 REMOVAL lt A E A eae 28 Installation oo ooooooooooooooo 28 Fuse Replacement 0 0cccoococoocooo no 29 Forward Reverse Cable Replacement 30 REMOVA eiii a ds ea 30 NSTallatiOlW msc aa aa ade ER 31 Steering Cable Replacement 32 REMOVAL ASA 32 Stat a a DA 33 Front Wheel Replacement 34 REMOVA mensa tad la bal 34 Installation o n a rr aa 34 Parking Brake Service 0oooooooooo 35 REMOVA asia esa Pu il alate 35 SIA ater it ia De ota aa a aed 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 3
10. four screws and remove pad 16 6 Label wire harnesses GUN 1 and GUN 2 Discon nect two wire harnesses from solenoids 7 Label gun cables Gun 1 and Gun 2 Disconnect gun cables from actuators Y E gt t119159a 8 Use a needle nose pliers to remove gun cables from bracket ti19667a 9 Use wrench to disconnect manifold tubes by the paint pump NOTE Oil will spill Use a rag to con tain the oil Wop K Q 00 Pg ti19160a 3A2593B Repair 10 Disconnect manifold tubes at manifold 11 Remove two mounting bolts and slide hydraulic manifold down and out from unit t119162a Installation 1 Slide hydraulic manifold in and up into unit Install and tighten two mounting bolts t119162a 2 Loosely install manifold tubes to manifold 3 Loosely install manifold tubes by the paint pump Tighten four nuts t119160a 3A2593B Repair 4 5 6 TE 8 9 Hydraulic Gun Manifold Replacement 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 Connect Gun 1 and Gun 2 cables to actuators t119159a Connect two wire harnesses to solenoids NOTE Be sure to connect Gun 1 to coil closest to center of sprayer Install pad and tighten four screws Install front shield to unit and t
11. information e Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces e Do not kink or over bend hoses or use hoses to pull equipment e Keep children and animals away from work area e Comply with all applicable safety regulations e Do not carry passengers e Check work area for reduced overhead clearance e g doorways tree branches parking ramp ceilings and avoid contacting them 3A2593B Repair 5 Warnings 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 z Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns e Do not touch hot fluid or equipment PERSONAL PROTECTIVE EQUIPMENT Wear appropriate protective equipment when in the work area to help
12. is disconnected or broken Reconnect or replace cable oN Reconnect or replace harness as Clutch wire harness is disconnected or broken P Machine will not drive necessary pressure See operation manual Prime drain valve is closed and system is pressurized engine Operates Dut Hydraulic fluid too low Shut off sprayer Add fluid displacement pump does not operate a lr Oe Ue OM POKON ORAN Replace oil reservoir belt See page 11 Tip is clogged Reverse tip to clean See manual 311254 Displacement pump piston rod is stuck due to dried paint Hydraulic motor not shiftin set pump valve OFF Turn pressure down Turn engine 2 OFF Pry rod up or down until hydraulic motor shifts 3A2593B Repair 39 Open prime drain valve Repair pump See manual 309277 Troubleshooting ano e ts Displacement pump operates but Pressure setting is too low Pressure setting is too low is too low Increase pressure Increase pressure See operation manual Increase pressure See operation manual manual Fluid filter or tip is clogged or dirty a en tip See operation manual or gun Engine speed is too low Increase throttle setting See operation manual Displacement pump operates but output mee vano Da en Clean intake valve See manual 309277 not seating properly is low on downstroke and or on both sides Pump packings are worn or damaged Replace pump packings See manual 309277 Use larger diameter hose and
13. or reduce overall length Large pressure drop in hose with heavy of hose Use of more than 100 ft x 1 4 in hose signifi materials cantly reduces performance of sprayer Use 3 8 in hose for optimum performance Pump is difficult to prime worn and that ball seats well Reassemble valve Engine speed is too high Decrease throttle setting before priming pump See operation manual Pump break in period takes up to 100 gallons Low stall or run pressure shown on New pump or new packings oe of material isplay Faultytransducer si Faultytransducer si Replace transducer Replace transducer Remove throat packing nut spacer Tighten throat Throat packing nut is loose Excessive paint leakage into throat packing nut just enough to stop leakage packing nut Throat packings are worn or damaged Replace packings See manual 309277 Displacement Displacement rod is worn or damaged is worn or Displacement rod is worn or damaged Replace rod Seemanual309277 rod Replace rod Seemanual309277 manual 309277 Check and tighten all fluid connections Reprime pump Air in pump or hose See operation manual Fluid is spitting from gun Tip is partially clogged Clear tip See manual 311254 as Refill fluid supply Prime pump See operation manual PPY Po Check fluid supply often to prevent running pump dry 40 3A2593B Repair Troubleshooting II Case Son encase E Parage Arouna mare Piston rod seal worn or damaged Repla
14. prevent serious injury including eye injury hearing loss inhalation of toxic fumes and burns This protective equipment includes but is not limited to e Protective eyewear and hearing protection e 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 Component Identification SERIAL PARTNO ti24911a Operator Platform Engine ON OFF Switch Paint Filter Hydraulic Fill Cap Dipstick Prime Drain Valve Hydraulic Oil Filter Displacement Pump Paint Hopper 25 gallon 95 liter Rear Gun Arm Mount Handle Bar Height Adjustment Knob 6 Serial Label Engine Recoil Handle Gun Tiger Sal 8 Wheel Motor Bypass Valve Steering Handle 9 Straight Line Adjuster 3A2593B Repair 7 Component Identification Controls Component Identification Controls t118719a 8 Engine Choke 7 Gun 1 Selector Gun 2 Selector EX Engine Kill Main Power Switch 10 12V Accessory Jack Pressure Control
15. 12 7 ft 3 75 to 3 87 m 38 5 Install wheel 16 and four lug nuts 22 ti18589a 6 Lower jack 7 Install front shield with six screws Y Sf E M7 gt gt Y VEZ Y h RE ti19200a 8 Install tank and siphon tube 9 Calibrate sprayer See operation manual 3A2593B Repair Troubleshooting Troubleshooting General Engine pulls hard aL MS ere oad Malt ponen Turn main power switch OFF 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 E Check oil level and add oil if necessary See engine Engine oil level is low ee Engine will not start 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 RR PRA PARES position P P Remove spark plug Pull starter 2 to 4 times Clean or Oil is seeping into combustion chamber replace spark plug Start engine Keep sprayer upright to avoid oil seepage Improperly adjusted high speed setting Reset high speed to 3600 3700 engine rpm at no load High engine speed at no load 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
16. 18562a 12 Turn on the Main Power Switch to engage clutch rt WA WAN ti18552a Slowly pull forward reverse control lever in forward and reverse directions 10 times t118718a 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 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 ti19669a The hydraulic gun manifold is self purging Turn engine off and check oil level Top off to Full range Full Range cold 3A2593B Repair Ground Drive Pump Replacement MA ADA 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 4 Disconnect all fittings and hoses from pump 63 NOTE Oil will spill out of hoses Have rags and waste pail nearby Ground Drive Pump Replacement 5 Rem
17. 37 and remove axle bolt 37 from fork 34 a a are pe or E a RAI gt A 39 S A fas 3 Remove two spacers 36 and wheel 35 from fork 34 34 Installation 1 Insert two spacers 36 into wheel 35 and slide into fork 34 e Ml pa a Ga PS 34 sb 2 A 29 Y 36 ti20125a 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 880 550 kPa 5 Remove jack stands and test drive sprayer to verify straight line tracking Adjust if necessary See Oper ation manual 3A2593B Repair Parking Brake Service AY 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 3 Use screwdriver to remove spring 15 Remove clip 13 and pin B 4 Replace damaged or worn parts 3A2593B Repair Parking Brake Service Installation 1 Install lever 14 with pin B and clip 13 2 Use screwdriver to install spring 15 3 Install levers 10 16 with three pins A and clips 13 4 Install fender wheel hub and tire See Wheel Motor Installation page 37 5 Adjust screw 17 to hold tire when brake lever 16
18. 7 Troubleshooting 000 ese eee eee ees 39 General vxcursdaian te ae Dada daa 39 Wiring Diagram o ooooooooooommmoo 43 WINN PARS LIS rica 44 Hydraulic Diagram 0 ooooooooooo oo 45 Hydraulic Parts List 46 Graco Standard Warranty 49 3A2593B Repair Models Models o Gm Pira Sp patos OOOO EXC IEC 7 24M608 1 No FiekdLazerG400 North America 16V470 DEN Yes 1 Tank LLIV 250 SPS Latin America Asia Pacific 16V471 MEN Yes 1 Tank LLIV 250 SPS Europe 16V473 Yes 1 Tank LLIV 250 SPS North America Latin America Asia Pacific 16V474 Yes 1 Tank LLIV 250 SPS Europe 24U561 Yes 2 Tanks LLIV 250 SPS North America Latin America Asia Pacific 3A2593B Repair 3 Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion 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 o TRAFFIC HAZARD Va Being struck by other vehicles may result in serious injury or death NO e Do not operate in traffic e Use appropriate traffic control in all traffic areas e Follow local highway and tr
19. 8 3A2593B Repair Grounding Procedure For Flammable Materials Only Mo 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 pave ment 2 Ground sprayer with grounding clamp Grounding clamp must attach to grounded object e g metal sign post E o QN RH ie T DY YY VY YOY VY YY ida lada ti3306a 3A2593B Repair Grounding Procedure For Flammable Materials Only Pressure Relief Procedure you see this symbol MO Mt A 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 paris follow the Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing the equipment Follow the Pressure Relief Procedure whenever 1 Perform Grounding Procedure if using flammable materials 2 Set pump valve OFF Turn engine OFF ti6740a 3 Turn pressure control to lowest setting Trigger gun to relieve pressure ti3305a PAINT ti3441a 4 Engage gun trigger safety Turn prime valve down Va a a Py No ti6473a ti3324a Ground Drive Belt Replacement Ground Drive Belt Repla
20. Repair O LineLazer IV 250sps Self Propelled Line Striper 3A2593B 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 e Read all warnings and instructions in this manual and the engine manual Save these instructions Related Manuals A AA PROVEN QUALITY LEADING TECHNOLOGY Table of Contents e O A obs Whew Merwe ee eel date ema es 3 WaIMINGS airada iaa 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 ecco Std toa Galeet eas ASR ee 10 HASTAN ATION ruda 10 Oil Reservoir Belt Replacement 11 REMOVAL rra ova cado 11 Installation ica 11 Hydraulic System Purging 12 Ground Drive Pump Replacement 13 REMOVAL aspas Ea 13 INSTA yu 13 Oil Reservoir Pump Replacement 14 Removal ii da Get al 14 Installati n yc o aaa als 14 Hydraulic Gun Manifold Replacement 16 Removal saia EU as 16 WISTANATION sidad 17 Paint Pump Replacement 18 Removal senda aras ea haces da 18 Installation wha se
21. a r daction du presente document sera en Anglais ainsi que tous documents avis et procedures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les proc dures concern es 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
22. ansportation 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 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 MPa bar PS Do not stop or deflect leaks with your hand body glove or rag
23. c system page 12 06881 FE 19 Clutch Replacement Clutch Replacement AY a 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 e US i GAO J ti19215a 4 Unscrew tensioning bolt from the ground drive pump bracket ENS ti19131a 5 Move ground drive pump assembly aside da gt AR S Y t119216a 20 Remove engine recoil starter and place a screw driver through the recoil starter cup Disconnect clutch connector to main wire harness t119212a 3A2593B Repair Clutch Replacement Installation 4 Install pulley 61 and torque three screws 81 to 10 ft lb 13 Nem 1 Install spacer 56 and key 60 onto crankshaft Slide clutch 57 onto crankshaft ti19216a 5 Install recoil starter onto engine ti19704a 6 Connect clutch to wire harness sa o LE t119211a E 3 Install heavy washer 58 and bolt 59 onto crank shaft Torque bolt to 45 5 ft lb 61 7 Nem Use screwdriver in recoil starter cup to hold crank shaft t119212a 7 Install ground drive pump assembly with tensioning and two hold down bolts Ni 3 Ve OAS 58 59 Q w gt Sy E 8 Install and tension Oil Reservoir Belt page 11 and Ground Drive Belt page 10
24. ce hydraulic motor piston rod wiper and seal motor piston rod wiper Paint buildup on hydraulic components Clean hydraulic components Sprayer overheats E ee Hydraulic oil level is low Fill with hydraulic oil See operation manual Low hydraulic fluid level Shut off sprayer Add fluid Excessive hydraulic pump noise 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 Reconnect or replace touch pad or damaged Display board failure Replace display board Fluid pressure not high enough Must be over 800 psi 55 bar for counter to add Check wires and connections Replace any broken Broken or disconnected wire Gallon liter counter not wires adding fluid volume Missing or damaged magnet Reposition or replace magnet Replace sensor See Hydraulic Motor Replacement Bad sensor page 19 Machine not calibrated Perform calibration procedure See Operation manual Distance not adding properly Rear tire pressure is too low or too high Adjust tire pressure to 55 5 psi 380 34 kPa MEASURE mode will be inaccurate Gear teeth missing or damaged and speed will be wrong pump side only Replace distance gear wheel hub Distance sensor is loose or broken Reconnect or replace sensor Distance sensor S
25. cement Removal AA va a 1 Loosen four screws and remove belt cover Q N gt y o N N af MA E M INIA A O AZ poe No gt xe A A LI RES NV X Z A K Sh G S Bo PN A ti19128a E 2 Loosen two hold down bolts 3 Loosen tension bolt to bring two pulleys closer 10 Installation 1 Install belt onto pulleys e XA ti19132a Ground Drive Belt Tension Recommendations dew Ba 53 2 Lbf 236 9 N 167 4 3 Hz 45 2 Lbf 200 9 N Used Belt 155 4 3 Hz Gates Sonic Tension Meter Settings M MASS 85 g m W of belts 1 S Span 157 mm 3 Install mounting plate and tighten two hold down bolts 3A2593B Repair Oil Reservoir Belt Replacement id AY d 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 LAN 3 Remove belt ASA TA ASS 191484 3A2593B Repair Oil Reservoir Belt Replacement Installation 1 Replace belt ES UL 2 Tighten two adjustment bolts evenly and maintain belt alignment Tighten belt to proper tension see table t119150a Oil Reservoir Be
26. dations 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 shal
27. ee 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 Pull back cover where remote cable connects to Pressure control knob does not rotate Knob is jammed hydraulic pump and turn counter clockwise ccw until free Set screw at hydraulic pump connection is Remove cover and tighten set screw Pressure control knob rotates freely loose Reassemble cover with no pressure change 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 Increase ground speed to be greater than 0 7 mph than 0 7 mph 1 1 kph 1 1 kph EN Increase fluid pressure up to at least Gun does not trigger y P 1000 psi Gun cable is disconnected or broken cable Gun cable is disconnected or broken disconnected or broken Reconnect or replace cable or Reconnect or replace cable cable Gun trigger control switch is disconnected or Reconnect or replace gun trigger control switch broken Disconnected or broken wires from control Reconnect or replace wires board to solenoid eu Gun cable is pinched or kinked Change gun cable routing or replace cable Gun triggering is slow System pressure is too low Increase fluid pressure up to at least 1000 psi
28. ement Remove six screws and control shroud G ti19701a Remove two toggle switch nuts from control panel SA ti19702a 10 Feed toggle switches through control panel ti20244a 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 ti20136a gt 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 ti19910a ti20245a 26 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 t119199a ZA 2 Connect all wires to control board See Wiring Diagram page 43 NS Sa A o Y i lt gt Vas 7 Pr ti19198a 3 If replacing display install display with four screws Install touchpad ribbon cable to display board Install display ribbon cable to control board Assem ble ferrite core on ribbon cable Install ferrite core to toggle switch bracket with two screws 4 If replacing toggle switches instal
29. emove four screws and pump from reservoir cover Installation Install pump onto oil reservoir cover with four screws t119671a If hydraulic oil is contaminated in reservoir drain reservoir and remove contamination Install oil reservoir cover with eight screws to the oil reservoir base Xi Ts ti2agi4a Sila Install pulley on pump shaft and maintain belt align ment to inner groove of the clutch pulley Tighten two pulley screws t119670a 3A2593B Repair 4 Turn pressure control knob clockwise until seated 5 Turn hydraulic pump pressure control clockwise until seated then counterclockwise 1 6 turn Z ti23906a 6 t119143a 3A2593B Repair Oil Reservoir Pump Replacement 7 Slide cable sleeve up and tighten screw oe AN Q Rey a CER QS ES 2 IE t119145a S 8 Connect three hydraulic hoses to fittings on oil reservoir Replace oil filter gt gt gt a 5 J ti24913a 9 Install and tension Oil Reservoir Belt page 11 and Ground Drive Belt page 10 10 Purge hydraulic system page 12 15 Hydraulic Gun Manifold Replacement Hydraulic Gun Manifold Replacement AY Removal 1 Remove tank lid and siphon tube 2 Remove tank from unit 3 Remove six screws from front shield e lt Q ti19163a o 4 Remove front shield from unit 5 Loosen
30. frame on two jack stands t118550a 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 a NY Lis ol Po AS S D t119695a 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 Se pio Ss E Yo E 48 a a A 5 e CY 3 K Ao Wa O 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 t119698a 3A2593B Repair Installation 1 Install new cable 48 by following same route as old cable is being removed 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 otherside B at of front for Ro o Z tex imo ti19685a 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 t119698a 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 o
31. from battery ti24917a 7 Remove battery 28 3A2593B Repair Fuse Replacement Fuse Replacement 3 If fuse is open a wire has shorted to the frame or auxiliary lighting requires too much power Check wiring or reduce auxiliary lighting before replacing 1 Remove fuse cover fuse 2 Use needle nose pliers to remove old fuse and 4 Use needle nose pliers to install new fuse inspect it for open circuit 5 Replace cover ti19209a 3A2593B Repair 29 Forward Reverse Cable Replacement Forward Reverse Cable Replacement iz AY Removal 1 Remove tank lid and siphon tube t119163a 4 Remove front shield from unit 5 Loosen four screws and remove belt cover a y Na LOY ti19128a 30 g 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 148 t119699a 7 Atthe 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 C YS TO Lp So NOY gt IE CES S 8
32. ighten six screws Install tank into unit and connect siphon tube NOTE The hydraulic gun manifold is self purging 17 Paint Pump Replacement Paint Pump Replacement 5 Use hammer to loosen pump jam nut 106 6 Slide down retainer 104 and remove pin 105 N hz 7 Unscrew and remove paint pump 107 MPa bar PSI E This equipment stays pressurized until pressure is manually relieved To help prevent serious injury Installation splashing fluid and moving parts follow the Pressure Relief Procedure when you stop spraying and before 2 Insert pump rod into hydraulic motor rod and install cleaning checking or servicing the equipment pin 105 and retainer 104 3 Thread pump 107 into hydraulic motor housing Removal until pump bottoms out Unscrew pump one full turn and orient pump outlet approximately 45 to clear 1 Perform Pressure Relief Procedure page 9 ball valve hose 2 Disconnect suction tube 120 4 Use hammer to tighten pump jam nut 106 3 Disconnect hose 123 and fitting 95 from paint 5 Install guard 114 with screw 115 and nut 116 pump 107 6 Install fitting 95 and connect hose 123 4 Remove screw 115 nut 116 and pump guard 114 7 Connect suction tube 120 t119138a NG 18 3A2593B Repair Hydraulic Motor Replacement O O A Mi This equipment stays pressurized until pressure
33. 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 3A2593B Repair Hydraulic Motor Replacement NOTICE Use a screwdriver to lift pump piston up to gain access to mounting bolts and avoid contact with pis ton 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 al 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 pis ton Contact with pump mounting bolts can scratch ti1 and damage the pump piston 2 3 4 o 6 Install pump counter 112 with two screws 113 Connect hose 111 and fitting 193 to fitting 196 Connect fitting 108 above ball valve 109 Install Paint Pump page 18 Purge hydrauli
34. iston FITTING long elbow hydraulic FITTING 90 degree w adjustable TUBE supply hydraulic Qty N NNA h bh _b hb bh Ref 194 196 197 198 309 320 327 333 350 351 366 370 371 372 Part 24M626 126082 126080 126081 16M160 28 7179 246173 122970 116829 16P776 117607 100139 15F519 119841 Description TUBE supply hydraulic FITTING tee 8 x 8 x 6 JIC FITTING tee street FITTING nipple 3 8 18 x 6 JIC COVER reservoir LL250 painted KIT repair pump 200HS KIT repair oil filter FITTING hydraulic FITTING 90 degree w adjustable o ring TUBE supply hydraulic FITTING elbow std thd PLUG pipe TUBE hydraulic supply FITTING tee branch Qty N a od o dh o ho ko N 3A2593B Repair Notes Notes N 4 3A2593B Repair 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 recommen
35. l 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 l
36. l toggle switches into toggle switch bracket Make sure to place spac ers between toggle switches and bracket Connect cable to toggle switch board 3A2593B Repair 5 Feed toggle switches through control panel and install two toggle switch nuts y ti19691a 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 9 Install pad and tighten four screws 3A2593B Repair Control Board Toggle Switches and Display Replacement 10 Install front shield and tighten six screws t119200a ti24917a 12 If control board was replaced calibrate distance sensor see Operation manual 27 Battery Replacement Battery Replacement Installation 1 Install battery mw EE To reduce the risk of shorting the battery always Removal connect NEGATIVE black wire last 1 Remove tank lid and siphon tube 2 Connect red wire to positive and black wire to A negative posts of the battery E ti24916a 2 Remove tank from unit 3 EN ti19163a 4 Remove front shield from unit 4 Install front shield and use wrench to tighten six 5 Remove hold down strap from battery l E screws into shield ti24918a NOTICE To reduce the risk of shorting the battery always dis connect NEGATIVE black wire first Disconnect two wires
37. lt Tension Recommendations i 2 Lbf 24 9 N Now mee 0 S2 RAS ON Frequency 114 2 Hz Tension 48 2Lbf 214 9N Used Belt 106 4 2 Hz Gates Sonic Tension Meter Settings M MASS 85 g m W of belts 1 S Span 236 mm 3 Tighten four hold down bolts ti19151a 4 Install Ground Drive Belt and tighten to proper tension see page 10 11 Hydraulic System Purging Hydraulic System Purging MO vi 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 oo E gt 9 L FOO j l t118587a Full Range cold U ENANA 3 Make sure drive wheel release is closed E SEa amp O 3 SA yA LX Sy 2 PIV ti
38. otor 3A2593B Repair Rear Wheel and Wheel Motors Wheel Motor Installation 2 Remove tank from unit 3 Use wrench to remove six screws from front shield and remove front shield from unit Ni GF dA A 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 Place jack under frame near pump side wheel and raise jack t118584a 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 ness 16 5 a y N y SR N 22 6 Purge hydraulic system See Hydraulic System Purging page 12 a t118589a t119328a Wheel Sensor Replacement 7 Use wrench to remove screw 6 clamp 5 and wheel sensor 4 Removal 1 Remove tank lid and siphon tube t119099a 3A2593B Repair 37 Rear Wheel and Wheel Motors Installation 1 Install wheel sensor 4 and clamp 5 with screw t119328a 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 t118564a t119329a NOTE Sensor is working properly if the measure display reads 12 3 to
39. ove nut 3 and disconnect tie rod 40 under neath 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 10 7 Purge Hydraulic System page 12 82 3A2593B Repair ti19135a 13 Oil Reservoir Pump Replacement Oil Reservoir Pump Replacement MO Mi A 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 t124913a 3 Loosen nut and slide cable sleeve down to gain access to cable set screw t119144a 4 Remove set screw and cable pump 14 6 Remove pulley from pump R
40. r amputate fingers and other body parts e Keep clear of moving parts e Do not operate equipment with protective guards or covers removed e 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 e Do not operate the unit when fatigued or under the influence of drugs or alcohol e Do not exceed the maximum working pressure or temperature rating of the lowest rated system compo nent See Technical Data in all equipment manuals e Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equip ment manuals Read fluid and solvent manufacturers warnings For complete information about your material request MSDS from distributor or retailer e Do not leave the work area while equipment is energized or under pressure e Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use e Check equipment daily Repair or replace worn or damaged parts immediately with genuine manufac turer s replacement parts only e Do not alter or modify equipment Alterations or modifications may void agency approvals and create safety hazards e Make sure all equipment is rated and approved for the environment in which you are using it e Use equipment only for its intended purpose Call your distributor for
41. ther side of handlebar ra Mo IEA j E TITTY III ti19685a 3A2593B Repair 5 Steering Cable Replacement 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 S N Y Ki amp D t119695a Verify that handlebar is aligned straight with frame If misaligned adjust nuts on cable 48 to straighten handlebar to frame 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 Install pad and tighten four screws Remove jack stands and test drive sprayer to check steering Adjust if needed Install cable ties in loca tions noted in step 10 of Removal Verify straight line tracking and adjust if necessary see Operation manual Install control shroud and tighten six screws Install front shield onto unit Use wrench to tighten six screws into front shield Install tank onto unit Install siphon tube and tank lid 33 Front Wheel Replacement Front Wheel Replacement AY Removal 1 Apply parking brake Raise front wheel off ground and support frame on two jack stands t119693a 2 Remove locknut 39 from axle bolt
Download Pdf Manuals
Related Search