Graco LineLazer IV 250SPS Repair Manual Download Page 25 | Manualshive

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Engine Replacement

3A2593C Repair

25

Engine Replacement

NOTE:

For Series C of 24F307, 24K960, 24K961,

24K962, 24M608 and Series B of 16V470, 16V471,
16V473, 16V474, 24U561

Removal

1. Remove clutch, see

Clutch Replacement,

page 21.

2. Disconnect two negative (black) battery wires at

battery. Negative battery post is located above plat-
form on the left side.

3. Disconnect seven wires from engine.

4. Remove air filter cover, element and base.

5. Disconnect throttle cable.

6. Disconnect choke cable.

7. Remove four mounting bolts from engine.

8. Remove engine.

NOTE:

Engine voltage regulator is

located below engine mounting plate. Remove two
screws and disconnect wires.

NOTICE

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

Engine Ground

Volt

a

ge Regul

a

tor

Ignition

St

a

rter Solenoid

B

a

ttery

ti2

3

921

ti19186a

ti19183a

ti19185a

ti19187a

ti19703a

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24
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27
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Summary of Contents for LineLazer IV 250SPS

Page 1: ... 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 Related Manuals 3A2090 Operation 3A2598 Parts 311254 Gun 309277 Pump 312307 Auto Layout Applications Methods 332230 Pressurized Bead System PBS 332226 Bead Gun Kit PBS Repair LineLazer IV 250SPS Self P...

Page 2: ...oval 21 Installation 22 Engine Replacement 23 Removal 23 Installation 24 Engine Replacement 25 Removal 25 Installation 26 Touch Pad Replacement 27 Removal 27 Installation 27 Control Board Toggle Switches and Display Replacement 28 Removal 28 Installation 29 Battery Replacement 31 Removal 31 Installation 31 Fuse Replacement 33 Forward Reverse Cable Replacement 34 Removal 34 Installation 35 Steering...

Page 3: ... B C 1 No LLIV 250SPS Europe 24K962 A B C 2 No LLIV 250SPS Europe 24M608 A B C 1 No FieldLazer G400 North America 16V470 A B 1 Yes 1 Tank LLIV 250 SPS Latin America Asia Pacific 16V471 A B 1 Yes 1 Tank LLIV 250 SPS Europe 16V473 A B 2 Yes 1 Tank LLIV 250 SPS North America Latin America Asia Pacific 16V474 A B 2 Yes 1 Tank LLIV 250 SPS Europe 24U561 A B 2 Yes 2 Tanks LLIV 250 SPS North America Lati...

Page 4: ...tic arc Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Ground all equipment in the work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail Do not use pail liners unless they are antistatic or conducti...

Page 5: ...D 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 a...

Page 6: ...d 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 preven...

Page 7: ...unt both sides 6 Serial Label under operator platform 7 Gun Trigger Lock 8 Wheel Motor Bypass Valve 9 Straight Line Adjuster 10 Engine ON OFF Switch manual start engine only 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 manual start engine only 16 Brake 17 Steering Handle 18 Front Gun Mount bot...

Page 8: ... Controls Manual Start Engine 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 2 1 on off 5 6 9 3 4 11 1 2 7 1 2 8 10 ti18719a ...

Page 9: ... Electric Start Engine 1 Engine Key Switch OFF ON START 2 Display 3 Forward Reverse Lever 4 Gun Trigger Control 5 Engine Throttle 6 Engine Choke 7 Gun 1 2 Selector 8 Engine Clutch 9 12V Accessory Jack both sides 10 Pressure Control 11 Hydraulic Pump Valve ti25621a 2 on off 5 6 8 3 4 11 1 2 7 9 10 ti25621a 1 ...

Page 10: ...ine OFF 3 Turn pressure control to lowest setting Trigger gun to relieve pressure 4 Engage gun trigger lock Turn prime valve down 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 ti23146a This equipment stays pressurized until pressure is manually relieved To help pr...

Page 11: ... onto pulleys 2 Tighten tensioning bolt to move two pulleys apart and tighten belt to proper tension see table 3 Tighten two hold down bolts 4 Replace belt cover and tighten four screws 5 If equipped with Pressurized Bead System install pressurized bead tanks and compressor see Pres surized Bead System manual 332230 ti19128a ti19130a ti19131a ti19133a Ground Drive Belt Tension Recommendations New ...

Page 12: ... Installation 1 Replace belt 2 Tighten two adjustment bolts evenly and maintain belt alignment Tighten belt to proper tension see table 3 Tighten four hold down bolts 4 Install Ground Drive Belt and tighten to proper tension see Ground Drive Belt Replacement page 11 ti19147a ti19146a ti19148a Oil Reservoir Belt Tension Recommendations New Belt Tension 55 2 Lbf 245 9 N Frequency 114 2 Hz Used Belt ...

Page 13: ...ain the spinning wheel to purge out the wheel that is not turning 7 Turn the prime valve down and open the hydraulic pump valve Allow the paint pump to stroke 10 times and then close the hydraulic pump valve 8 The hydraulic gun manifold is self purging 9 Turn engine off and check hydraulic oil level Top off to Full range This equipment stays pressurized until pressure is manually relieved To help ...

Page 14: ...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 11 7 Purge Hydraulic System page 13 This equ...

Page 15: ...four screws Make sure the five o rings are in place 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 align ment to inner groove of the clutch pulley Tighten two pulley screws This equipment stays pressurized until pressure is manually reli...

Page 16: ...mp pressure control clockwise until seated then counterclockwise 1 6 turn Install cable and tighten two set screws 6 Slide cable sleeve up and tighten screw 7 Connect three hydraulic hoses to fittings on oil reservoir Replace oil filter 8 Install and tension Oil Reservoir Belt page 12 and Ground Drive Belt page 11 9 Fill reservoir and purge hydraulic system page 13 ti19143a ti23905a ti23906a ti191...

Page 17: ...crews and pad 5 Label wire harnesses GUN 1 and GUN 2 Discon nect two wire harnesses from solenoids 6 Label gun cables Gun 1 and Gun 2 Disconnect gun cables from actuators 7 Use a needle nose pliers to remove gun cables from bracket 8 Use wrench to disconnect manifold tubes by the paint pump NOTE Oil will spill Use a rag to con tain the oil ti24196a ti24916a ti19163a ti19164a ti19161a Gun 2 Gun 1 t...

Page 18: ...t pump Tighten four nuts 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 7 Install pad and tighten four screws 8 Install front shield to unit and tighten ...

Page 19: ...tor 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 as noted in Removal step 3 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 This equipment stays pressurized until pressure is ...

Page 20: ...96 4 Connect fitting 108 above ball valve 109 5 Install Paint Pump page 19 6 Purge hydraulic system page 13 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 equipme...

Page 21: ...ew tensioning bolt from the ground drive pump bracket 5 Move ground drive pump assembly aside 6 Remove three bolts 81 and pulley 61 7 Remove engine recoil starter and place a screw driver through the recoil starter cup 8 Remove center bolt 59 and remove clutch 57 9 Disconnect clutch connector to main wire harness ti19215a ti19131a ti19213a ti19216a 81 61 ti19697a ti19696a ti19214a 56 60 58 59 57 t...

Page 22: ...1 7 N m Use screwdriver in recoil starter cup to hold crank shaft 4 Install pulley 61 and torque three screws 81 to 10 ft lb 13 N m 5 Install recoil starter onto engine 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 12 and Ground Drive Belt page 11 ti19214a 56 60 58 59 57 ti19211a ti19692a ...

Page 23: ...onnect 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 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 NOTICE To reduce the risk of...

Page 24: ...oke cable wire into hex shaped pivot c Insert cable sheathing under cable clamp and tighten screw 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 ...

Page 25: ...the left side 3 Disconnect seven wires from engine 4 Remove air filter cover element and base 5 Disconnect throttle cable 6 Disconnect choke cable 7 Remove four mounting bolts from engine 8 Remove engine NOTE Engine voltage regulator is located below engine mounting plate Remove two screws and disconnect wires NOTICE To reduce the risk of battery damage and shorts always disconnect NEGATIVE black ...

Page 26: ...w on hex shaped pivot e Verify proper operation of engine choke 4 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 5 Install air filter base element and cover 6 Connect seven wires to engi...

Page 27: ...l shroud 2 Disconnect ribbon cable from touch pad at display board 3 Peel off touch pad and remove adhesive from sheet metal 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 ti19098a ti19910a ti19910a ti19098a ...

Page 28: ...siphon tube 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 7 Remove six screws and control shroud 8 Remove two screws and splash shield 9 Remove two toggle switch nuts from control panel 10 Feed toggle switches through control panel ti24916a ti24916a ti19163a ti19164a ti19098a ti19701a ti19702a ti20244...

Page 29: ... 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 Diagrams pages 49 or 50 and select the correct model and series 3 If replacing display install display with four screws Install touchpad ribbon cable to display board Install display ribbon cable to control board ...

Page 30: ... 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 10 Install front shield and tighten six screws 11 Install tank lid and siphon tube 12 If control board was replaced calibrate distance sensor see Operation manual ti19691a ti19705a ti19098a ti19171a ti19200a ti24917a ti24917a ...

Page 31: ...nnect 1 or 2 black wires from battery 5 Lift battery and slide it back onto the platform Dis connect 1 or 2 red wires from battery 6 Remove battery Installation 1 Place battery on operator platform Connect 1 or 2 red wires to positive post of the battery NOTICE To reduce the risk of battery damage and shorts always disconnect NEGATIVE black wire first ti24079b NOTICE To reduce the risk of battery ...

Page 32: ...2593C Repair 2 Pickup and slide battery into mounting position Install battery hold down strap 3 Connect 1 or 2 black wires to negative post of the battery 4 Place coiled paint hoses over bracket and secure with straps ti24104b ...

Page 33: ...e 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 ti19209a ...

Page 34: ...rews and remove belt cover 7 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 8 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 14...

Page 35: ...stall 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 sipho...

Page 36: ...ar Remove ball joint 40 from cable 48 and save if not replacing Loosen two nuts on cable 48 and remove from bracket 5 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 6 Note position of cable 48 and cut off all cable ties that retain cable to frame Install new cable as o...

Page 37: ...de 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...

Page 38: ...om fork 34 Installation 1 Insert two spacers 36 into wheel 35 and slide into 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 Remove jack stands and test drive sprayer to verify straight line tracking Adjust if necessary see Op...

Page 39: ...d pin B 4 Replace damaged or worn parts 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 41 5 Adjust screw 17 to hold tire when brake lever 16 is depressed 16 17 13 13 A B 15 14 10 A A ti19684a A A 14 A 15 B 13 16 10 17 16 17 13 13...

Page 40: ...ocks 3 Inflate rear tires to 55 5 psi 380 34 kPa Wheel Motor Removal 1 Place jack under frame near wheel and raise jack 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 4 Remove screw 6 and distance sensor 4 with clamp 5 5 Remove four bolts 78 lock nuts 79 and fender 19 6 Disconnect two hydraulic hose...

Page 41: ...tighten lug nuts opposite each other 6 Purge hydraulic system See Hydraulic System Purging page 13 Wheel Sensor Replacement Removal 1 Remove tank lid and siphon tube 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 6 Disconnect wheel senso...

Page 42: ...UP 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 5 Install wheel 16 and four lug nuts 22 6 Lower jack 7 Install front shield with six screws 8 Install tank and siphon tube 9 Calibrate sprayer See operation manual ti19328a ti19329a ti18564a ti1858...

Page 43: ... oil if necessary See engine manual Engine is cold Use engine choke Spark plug cable is disconnected or damaged Connect spark plug cable or replace spark plug cable Main power switch is stuck in engine stop position Replace main power switch Key switch is defective Replace key switch Main wire harness is disconnected or defective Reconnect or replace main wire harness High engine speed at no load ...

Page 44: ...ow 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 Larg...

Page 45: ...hydraulic oil See operation manual Excessive hydraulic pump noise Low hydraulic fluid level Shut off sprayer Add fluid Pulleys loose on hydraulic pumps Remove belt guard Check and tighten loose pulley Display does not turn on Main power switch is not turned ON Turn main power switch ON Key switch is not turned ON Turn key switch to ON position Main fuse is blown Replace fuse See Fuse Replacement p...

Page 46: ... and speed is less than 0 7 mph 1 1 kph Increase ground speed to be greater than 0 7 mph 1 1 kph System pressure is too low Increase fluid pressure up to at least 1000 psi Gun cable is disconnected or broken Reconnect or replace cable Gun trigger control switch is disconnected or broken Reconnect or replace gun trigger control switch Disconnected or broken wires from control board to solenoid Reco...

Page 47: ...Hydraulic Diagram 3A2593C Repair 47 Hydraulic Diagram 196 189 2 2 22 63 191 166 166 350 327 110 111 366 108 109 198 197 190 333 350 193 194 189C 371 189A 189B 3YY 370 366 372 309 320 ti24964a ...

Page 48: ...C925 MANIFOLD hydraulic two piston 1 191 116829 FITTING 90 degree w adjustable 2 193 24M625 TUBE supply hydraulic 1 194 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 16X083 KIT repair pump 250 SPS 1 333 122970 FITTING hydraulic 1 350 116829 FITTING 90 de...

Page 49: ...D 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 NOTE For Series A B of 24F307 24K960 24K961 24K962 24M608 and Series A of 16V470 16V471 16V473 16V474 24U561 ...

Page 50: ... 17C925 MANIFOLD hydraulic two piston 1 189a 24N577 COIL solenoid hydraulic manifold included in 189 2 214b 24N565 KIT repair control board 1 214c 24N564 KIT repair display board 1 214e 16N374 SWITCH membrane 1 214f 24N566 KIT repair switch board 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 ...

Page 51: ...D LUG 187 238 237 221 150 RED BLACK TO GROUND LUG 222 GRAY TO ENGINE 57 214t 214f 214b 134 CONTROL BOARD SWITCH BOARD SWITCH HARNESS 214h CLUTCH SWITCH RED BLACK BLACK RED BLACK TO GROUND LUG 220 WHITE RED RED BLUE WHITE BLACK RED BLACK 224 225 54 BLACK RED 92 91 KEY SWITCH ti25644a Wiring Diagram Electric Start NOTE For Series C of 24F307 24K960 24K961 24K962 24M608 and Series B of 16V470 16V471 ...

Page 52: ...5753 BATTERY 33 AH sealed 1 187 237686 WIRE ground assembly w clamp 1 189 17C925 MANIFOLD hydraulic two piston 1 214b 24N565 KIT repair control board 1 214c 24N564 KIT repair display board 1 214e 16N374 SWITCH membrane 1 214f 24N566 KIT repair switch board 1 214h 17C063 SWITCH rocker spst 1 214j 16X075 SWITCH key switch 1 214t 16P019 HARNESS switch board 1 220 16X078 HARNESS wire LL250DC 1 221 16N...

Page 53: ...Notes 3A2593C Repair 53 Notes ...

Page 54: ...isclose 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 fo...

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