Graco LineLazer IV 250DC Repair Instructions

Self-propelled line striper

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Repair

LineLazer IV 250

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.

Be familiar with the controls and the proper usage of the equipment.

Save these instructions.

Pressurized

Model

Guns

Bead System

24U242

24U243

Yes

24U810

24U820

Yes

Related Manuals:

333388

Operation

334054

Parts

311254

Gun

309277

Pump

312307

Auto-Layout Applications Methods

332230

Pressurized Bead System (PBS)

Description

LLIV 250DC

334053C

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Summary of Contents for Graco LineLazer IV 250DC

Page 1 Repair LineLazer IV 250 Self-Propelled Line Striper 334053C 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.
Page 2 Removal ......25 Graco Standard Warranty ....54 Installation .
Page 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.
Page 4 Warnings WARNING PRESSURIZED ALUMINUM PARTS HAZARD Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage. • Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids con- taining such solvents.
Page 5 Warnings WARNING BATTERY HAZARD The battery may leak, explode, cause burns, or cause an explosion if mishandled. Contents of an open battery can cause severe irritation and/or chemical burns. If on skin, wash with soap and water. If in eyes, flush with water for at least 15 minutes and get immediate medical attention.
Page 6 Component Identification (Striper) Component Identification (Striper) Serial Label under operator platform Paint Filter, both sides Rear Gun Arm Mount, both sides Adjustable Pad Hydraulic Fill Cap / Dipstick Engine Fuel Cap Prime / Drain Valve, both sides Wheel Motor Bypass Valve Handle Bar Height Adjustment Knob Straight Line Adjuster Two Paint Hoppers (15 gallon / 56 liter)
Page 7 Component Identification (Controls) Component Identification (Controls) ti23143a Gun Trigger Control 12V Accessory Jack Gun 1, 2, 3 Selector Engine Key Switch, Off - On - Start Display Engine Clutch Switch Forward / Reverse Lever Engine Choke Pressure Control Engine Throttle Hydraulic Pump Valve, both sides 334053CRepair...
Page 8 Grounding Procedure (For Flammable Materials Only) Grounding Procedure Pressure Relief Procedure (For Flammable Materials Only) This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury This equipment must be grounded to reduce the risk from pressurized fluid, such as skin injection, of static sparking.
Page 9 Ground Drive Belt Replacement Ground Drive Belt Installation Replacement 1. Install belt onto pulleys. Removal ti19134a 1. If equipped with a Pressurized Bead System, remove pressurized bead tanks and compressor, 2. Tighten tensioning bolt to move two pulleys apart see Pressurized Bead System manual 332230. and tighten belt to proper tension (see table).
Page 10 Oil Reservoir Belt Replacement Oil Reservoir Belt Installation Replacement 1. Replace belt. Removal ti19149a NOTE: Ground drive belt must be removed before oil 2. Tighten two adjustment bolts evenly and maintain reservoir belt can be replaced, see Ground Drive Belt belt alignment.
Page 11 Hydraulic System Purging Hydraulic System Purging 4. Start engine and run at low speed. 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.
Page 12 Hydraulic System Purging 7. Turn the prime valve down and open the hydraulic 8. Repeat step 7 for the other pump. pump valve. Allow the paint pump to stroke 10 times 9. The hydraulic gun manifold is self-purging. and then close the hydraulic pump valve. 10.
Page 13 Ground Drive Pump Replacement Ground Drive Pump 5. Remove nut (3) and disconnect tie rod (40) under- neath pump (63). Replacement 6. Remove two mounting bolts (82) and washers (55) to remove pump (63) from bracket. Installation This equipment stays pressurized until pressure is 1.
Page 14 Oil Reservoir Pump Replacement Oil Reservoir Pump 4. Loosen two set screws and cable. Replacement ti19142a This equipment stays pressurized until pressure is 5. Remove eight screws and oil reservoir cover with manually relieved. To help prevent serious injury pump. from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before...
Page 15 Oil Reservoir Pump Replacement Installation 3. Install pulley on pump shaft and maintain belt align- ment to inner groove of the clutch pulley. Tighten two pulley screws. 1. Install pump onto oil reservoir cover with four screws. Make sure the five o-rings are in place. ti19670a ti19671a 4.
Page 16 Oil Reservoir Pump Replacement 6. Install cable and tighten two set screws. 8. Connect five hydraulic hoses to fittings on oil reservoir. Replace oil filter. ti19143b 7. Slide cable sleeve up and tighten screw. ti19145a ti23901a 9. Install and tension belts, see Oil Reservoir Belt Replacement, page 10 and Ground Drive Belt Replacement, page 9.
Page 17 Hydraulic Gun Manifold Replacement Hydraulic Gun Manifold 4. Remove four screws and pad. Replacement Removal ti19164a 1. Remove tank lids and siphon tubes. 5. Label wire harnesses GUN 1, GUN 2, and GUN 3. Disconnect three wire harnesses from solenoids. Gun 3 Gun 2 Gun 1...
Page 18 Hydraulic Gun Manifold Replacement Installation 7. Use a needle-nose pliers to remove gun cables from bracket. 1. Slide hydraulic manifold in and up into unit. Install and tighten two mounting bolts. ti23911a 8. Use wrench to disconnect manifold tubes by the paint pump.
Page 19 Hydraulic Gun Manifold Replacement 4. Observe label on bracket. Push labeled gun cables 6. Connect three wire harnesses to solenoids. into manifold brackets. Gun 3 Gun 2 Gun 1 ti23916a 7. Install pad and tighten four screws. 8. Install front shield to unit and tighten six screws. ti23964a 5.
Page 20 Paint Pump Replacement Paint Pump Replacement This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.
Page 21 Hydraulic Motor Replacement Hydraulic Motor Installation Replacement 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 pis- ton. Contact with pump mounting bolts can scratch This equipment stays pressurized until pressure is and damage the pump piston.
Page 22 Clutch Replacement Clutch Replacement 6. Remove three bolts (81) and pulley (61). Removal 1. Remove ground drive belt, page Ground Drive Belt Replacement, page 9. ti19216a 2. Remove oil reservoir belt, see Oil Reservoir Belt 7. Remove engine recoil starter and place a screw- Replacement, page 10.
Page 23 Clutch Replacement 9. Disconnect clutch connector to main wire harness. 3. Install heavy washer (58) and bolt (59) onto crank- shaft. Torque bolt to 45 +/- 5 ft-lb (61 +/- 7 N•m). Use screwdriver in recoil starter cup to hold crankshaft. ti19212a Installation ti19692a...
Page 24 Clutch Replacement 6. Connect clutch to wire harness. 7. Install ground drive pump assembly with tensioning and two hold-down bolts. ti19908a ti19212a 8. Install and tension belts, see Oil Reservoir Belt Replacement, page 10 and Ground Drive Belt Replacement, page 9. 334053CRepair...
Page 25 Engine Replacement Engine Replacement 5. Disconnect throttle cable. Removal 1. Remove clutch, see Clutch Replacement, page 22. NOTICE ti19183a NOTICE 6. Disconnect choke cable. To reduce the risk of battery damage and shorts, always disconnect NEGATIVE (black wire) first. 2. Disconnect two negative (black) battery wires at battery.
Page 26 Engine Replacement Installation 4. Install throttle cable. a. Place speed lever to high speed. 1. Install engine voltage regulator below engine b. Insert “Z” bend wire into hole furthest from pivot. mounting plate with two screws. Connect regulator c. Place cable sheathing under clamp and pull to wire harness.
Page 27 Touch-Pad Display Touch-Pad Display ti23924a 2. Display kit. Remove protective film from display NOTICE face. a. Torque screws to 3-5 in-lb (0.34-0.56 N•m) To avoid electrostatic-discharge (ESD) always use wrist strap 112190 when servicing the touch-pad 3. Membrane switch kit. display.
Page 28 Control Board Replacement Control Board Replacement 5. Remove four screws and remove pad. Removal 1. To disconnect power remove fuse, see Fuse Replacement, page 33. 2. Remove siphon tubes and lids. ti23930a 6. Remove six screws and control shroud. 3. Remove tanks from unit. 4.
Page 29 Control Board Replacement 7. Remove two screws and splash shield. 3. Connect all wires to control board. See, Wiring Dia- gram, page 50. Pump number 1 is on the left when you stand in the operator position. 4. Bundle and secure wires with a cable tie just inboard of the choke cable.
Page 30 Control Board Replacement 10. Install front shield and tighten six screws. 11. Install tanks, lids and siphon tubes. ti19200a 12. If control board was replaced select language, units, and calibrate distance sensor (see Operation manual). 334053CRepair...
Page 31 Battery Replacement Battery Replacement 5. Lift battery and slide it back onto the platform. Dis- connect two red wires from battery. Removal 1. Battery may be removed from the back of the unit by sliding it out above the operator platform. 2.
Page 32 Battery Replacement 2. Pickup and slide battery into mounting position. 4. Place coiled paint hoses over bracket and secure Install battery hold down strap. with straps. 3. Connect two black wires to negative (–) post of the battery. ti24104a 334053CRepair...
Page 33 Fuse Replacement Fuse Replacement 3. If fuse is open, a wire has shorted to the frame or aux- iliary lighting requires too much power. Check wiring or reduce auxiliary lighting before replacing fuse. 1. Remove fuse cover. 4. Use needle-nose pliers to install new fuse. 2.
Page 34 Forward/Reverse Cable Replacement Forward/Reverse Cable Replacement Removal 1. If equipped with a Pressurized Bead System, remove pressurized bead tanks and compressor. See Pressurized Bead System manual 332230. ti19128a 2. Remove tank lids and siphon tubes. 6. At the handlebar, remove locknut (3) and ball joint (40) from handlebar forward/reverse lever.
Page 35 Forward/Reverse Cable Replacement Installation 4. Verify that the handlebar forward/reverse lever does not touch handlebar grips. Adjust cable and ball joints if needed. 1. Install new cable (148) by following same route as old cable is being removed. 5. Install belt cover and tighten four screws. 2.
Page 36 Steering Cable Replacement Steering Cable Replacement 3. Remove six screws and control shroud. Removal NOTE: Both cables must always be replaced, even if only one failed. Repeat steps 5-7 for each cable. 1. Perform Pressure Relief Procedure, page 8. 2. Loosen four screws and remove pad. ti23931a ti23930a 334053CRepair...
Page 37 Steering Cable Replacement 4. Apply parking brake. Raise front wheel off the 5. At the handlebar, remove locknut (3) and ball joint ground and support frame on two jack stands. (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.
Page 38 Steering Cable Replacement Installation Both cables must always be replaced, even if only one failed. Repeat steps 1-8 for each cable. 1. Install new cable (48) by following same route as old cable being removed. NOTE: Steps 2-4 pertain to front wheel only. 2.
Page 39 Steering Cable Replacement 8. Verify handlebar is aligned straight with the frame. If 10. Mark the front adjustment nut (50) to note current misaligned, turn adjustment nut (49) to straighten position, then back off three full rotations. Tighten the handle. rear adjustment nut (49) until frame is secured between both adjustment nuts.
Page 40 Front Wheel Replacement Front Wheel Replacement Installation 1. Insert two spacers (36) into wheel (35) and slide into fork (34). Removal 1. Apply parking brake. Raise front wheel off ground and support frame on two jack stands. ti20125a ti19693a 2. Insert axle bolt (37) through fork (34), spacers (36) 2.
Page 41 Parking Brake Service Parking Brake Service Removal 1. Remove tire, wheel hub, and fender. See, Wheel Motor Removal, page 42. 2. Remove clips (13) from three pins (A). Remove pins and levers. 3. Use screwdriver to remove spring (15). Remove clip (13) and pin (B).
Page 42 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. ti18589a Rear Wheel Installation ti23945a 1. Replace wheel and install lug nuts. Alternately 4.
Page 43 Rear Wheel and Wheel Motors Wheel Motor Installation 1. Connect two hydraulic hoses (112) to wheel motor (21a) and insert wheel motor (21a) into frame (1). 2. Install wheel motor (21a) and fender (19) with four bolts (78) and lock nuts (79). 3.
Page 44 Rear Wheel and Wheel Motors 5. Use wrench to remove screw (6), clamp (5), and wheel sensor (4). ti18564a ti19329a NOTE: Sensor is working properly if the measure display reads 12.3 to 12.7 ft (3.75 to 3.87 m). 5. Install wheel (16) and four lug nuts (22). ti23946a ti18589a Installation...
Page 45 Notes Notes 334053CRepair...
Page 46 Troubleshooting Troubleshooting General Problem Cause Solution Turn key switch to ON. Choke engine and pull recoil Battery is discharged. starter rope. Engine will not crank Key switch is defective. Replace key switch. Main wire harness is defective. Replace wire harness, see Wiring Diagram, page 50. Excessive hydraulic load.
Page 47 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.
Page 48 Troubleshooting Problem Cause Solution Turn pressure adjusting knob clockwise to increase Pressure setting too low. pressure. See Operation manual. Low stall or run pressure shown on Pump break-in period takes up to 100 gallons display New pump or new packings. of material.
Page 49 Gun does not apply dots Dot size setting is too small Increase dot size. Pressure is too low Increase pressure to 1000 psi. Use only Graco approved hydraulic fluid 169236 (5 gallons / 18.9 liter) or 207428 (1 gallon / 3.8 liter) 334053CRepair...
Page 50 Wiring Diagram Wiring Diagram ti23961a 334053CRepair...
Page 51 Wiring Diagram Wiring Parts List Ref. Part Description Qty. Ref. Part Description Qty. 214b 24V561 KIT, repair, control board 15K357 SENSOR, distance 17C063 SWITCH, rocker, SPST 24U562 KIT, repair, engine, GX390 16X075 SWITCH, ignition (includes 54a) 24U233 CABLE, 18 conductor 24N502 VOTLAGE REGULATOR 16N401 SWITCH, pushbutton 125877 CLUTCH, electric, LL250...
Page 52 Hydraulic Diagram Hydraulic Diagram ti23962a 334053CRepair...
Page 53 Hydraulic Diagram Hydraulic Parts List Ref. Part Description Qty. Ref. Part Description Qty. 124941 FITTING, long elbow, hydraulic 125929 MOTOR, wheel 116829 FITTING, 90 degree, w/adjustable 16M271 HOSE, coupled, assembly, LL250 24M625 TUBE, supply, hydraulic 247930 KIT, repair, hydraulic pump 24M626 TUBE, supply, hydraulic 16X838 HOSE, hydraulic, supply 2nd pump 126082 FITTING, tee, #8 x #8 x #6 JIC...
Page 54 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.

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