Graco LineDriver ES 25U670 Use and care manual

Operation, Repair, Parts
LineDriver® ES Lithium 3A9034B
EN
For the propulsion of line striping and removal equipment. For professional use only. Not
approved for use in explosive atmospheres or hazardous (classified) locations.
Models: 25U670, 25U671
10 mph (16 kph) Maximum Operating Speed
Important Safety Instructions
Read all warnings and instructions in this manual and in related
LineLazer®, GrindLazer® and ThermoLazer® manuals before using the
equipment. Save these instructions.
Related Manuals:
Power Sonic Quick Guide (Scan QR code below)
710-0138 Delta-Q Battery Charger
3A6720 Hitch Receiver Kit
LineDriver ES Lithium
Model Series Cord Adapter
--- 25U670 B North America
25U671 B
North America
Australia
CEE 7/7
Denmark
Italy
Switzerland
United Kingdom
Use only genuine Graco replacement parts.
The use of non-Graco replacement parts may void warranty.

2 3A9034B
Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component Identification . . . . . . . . . . . . . . . . . . . . 6
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12V Auxiliary Ports. . . . . . . . . . . . . . . . . . . . . . . . 7
Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Know Your Controls . . . . . . . . . . . . . . . . . . . . . . . 8
Daily Inspections . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Differences in Operation . . . . . . . . . . . . . . . . . . 10
How to Operate . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operating on Inclines . . . . . . . . . . . . . . . . . . . . . 11
Trailer Loading & Unloading . . . . . . . . . . . . . . . . 11
Charging the Batteries . . . . . . . . . . . . . . . . . . . . 12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Parking/Emergency Brake Adjustment or
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 14
Throttle Linkage Adjustment . . . . . . . . . . . . . . . 15
Coupler Adjustment . . . . . . . . . . . . . . . . . . . . . . 16
Accelerator Calibration (Using Kit 25N880) . . . . 17
Transaxle Service . . . . . . . . . . . . . . . . . . . . . . . . 18
Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Battery Pack Replacement. . . . . . . . . . . . . . . . . 19
Transaxle Replacement . . . . . . . . . . . . . . . . . . . 20
Traction Motor Replacement . . . . . . . . . . . . . . . 20
Motor Controller Replacement . . . . . . . . . . . . . . 20
Recycling and Disposal . . . . . . . . . . . . . . . . . . . . . 21
Rechargeable Battery Disposal . . . . . . . . . . . . . 21
End of Product Life. . . . . . . . . . . . . . . . . . . . . . . 21
Troubleshooting - LineDriver . . . . . . . . . . . . . . . . . 22
Troubleshooting - Motor Controller . . . . . . . . . . . 23
Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Parts Drawing - Detail Views . . . . . . . . . . . . . . . . . 30
Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Wiring Diagram - Harness 25N661 . . . . . . . . . . . . 34
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Wiring Diagram - Harness 25E406 . . . . . . . . . . . . 36
Technical Specifications . . . . . . . . . . . . . . . . . . . . 37
Graco Standard Warranty. . . . . . . . . . . . . . . . . . . . 39
Graco Information. . . . . . . . . . . . . . . . . . . . . . . . . . 39

Warnings
3A9034B 3
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation
point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these
symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard
symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
MOVING VEHICLE HAZARD
Careless and reckless behavior causes accidents. Falling from vehicle, running into people or objects, or being
struck by other vehicles may result in serious injury or death.
• Do not operate unless attached to line striping or line removal equipment.
• Do not step on Direction/Speed Pedals.
• Make turns slowly. Do not make turns greater than 45°.
• Loss of traction may occur going downhill.
• Do not operate on inclines greater than 7.5°.
• Do not carry passengers.
• Do not tow.
• Use with line striping or line removal equipment only.
• Use appropriate traffic control in all traffic areas. Refer to manual on Uniform Traffic Control Devices (MUTCD), U.S.
Department of Transportation, Federal Highway Administration or local highway and transportation regulations.
TRAFFIC HAZARD
Vehicle strikes may result in serious injury or death.
• Do not operate in traffic.
• Use traffic control.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric
shock.
• Turn off and disconnect power cord before servicing equipment.
• Connect only to grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on power and extension cords.
• Do not expose to rain. Store indoors.
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.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’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.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe burns:
• Do not touch hot fluid or equipment.

Warnings
4 3A9034B
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.
• Replace battery only in a well-ventilated area and away from flammable or combustible materials,
including paints and solvents.
• When battery is not in use, keep it away from metal objects like keys, nails, screws or other metal objects
that can short circuit the battery terminals.
• Do not throw into fire.
• Charge only with Graco approved charger as listed in this manual.
• Do not store or charge at temperatures below 32° or above 113°F (0° to 45°C).
• Do not use at temperatures below 14° or above 140°F (-10° to 60°C).
• Do not expose battery to water or rain.
• Do not disassemble, crush, or penetrate the battery.
• Do not use or charge a battery that is cracked or damaged.
• Follow local ordinances and/or regulations for disposal.
CHARGER ELECTRIC SHOCK, FIRE AND EXPLOSION HAZARD
Improper setup or usage can cause electric shock, fire, and explosion.
• Charge only in a well-ventilated area and away from flammable or combustible materials, including paints
and solvents.
• Do not charge on a combustible or flammable surface.
• Do not leave battery unattended while charging.
• Immediately unplug charger when charging is complete.
• Charge only Graco approved batteries listed in this manual; other batteries may burst.
• Use only in dry locations. Do not expose to water or rain.
• Do not use a charger that is cracked or damaged.
• If the supply cord is damaged, replace the charger or cord, depending on model.
• Disconnect the charger from the outlet before cleaning.
• Ensure that the outside surface of the battery is clean and dry before plugging into the charger.
• Do not attempt to charge non-rechargeable batteries.
• Do not disassemble the charger. Take charger to authorized service center when service or repair is
required.

Warnings
3A9034B 5
GROUNDING
This product must be grounded. In the event of an electrical short circuit, grounding reduces the risk of
electric shock by providing an escape wire for the electric current. This product is equipped with a cord
having a grounding wire with an appropriate grounding plug. The plug must be plugged into an outlet that is
properly installed and grounded in accordance with all local codes and ordinances.
• Improper installation of the grounding plug is able to result in a risk of electric shock.
• When repair or replacement of the cord or plug is required, do not connect the grounding wire to either
flat blade terminal.
• The wire with insulation having an outer surface that is green with or without yellow stripes is the
grounding wire.
• Check with a qualified electrician or serviceman when the grounding instructions are not completely
understood, or when in doubt as to whether the product is properly grounded.
• Do not modify the plug provided; if it does not fit the outlet, have the proper outlet installed by a qualified
electrician.
• This product is for use on a nominal 120V or 230V circuit and has a grounding plug similar to the plugs
illustrated below.
• Only connect the product to an outlet having the same configuration as the plug.
• Do not use an adapter with this product.
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. 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.
120V US 230V

Component Identification
6 3A9034B
Component Identification
1 Headlight
2 Direction/Speed Pedals
3 Step Plate
4 Hitch
5 Coupler
6 Safety Pin Location
7 Handle Open
8 Handle Locked
9 Parking/Emergency Brake
10 Tool Tray
11 Seat Adjustment
12 Operator Seat
13 Serial ID
14 Power Switch
15 Speed Switch
16 ExactMil™ Speed Control
17 Voltage Meter
18 12V Aux. Power
19 Light Socket
20 Motor Controller Diagnostic Light
21 Battery Charger
22 Seat Lid
23 Buzzer
24 Seat Cover
25 Seat Interlock Switch

Setup
3A9034B 7
Setup
1. Install supplied ramp onto pallet.
2. Connect Hitch Receiver to line striping or line
removal equipment - Hitch Receiver Kit 25N787;
Manual 3A6720.
3. Install LineDriver Coupler to striper or grinder hitch
ball.
4. Latch Coupler to locked position (M).
NOTE: If Coupler is too tight to latch or is loose after
latching, Coupler needs adjustment. Refer to Coupler
Adjustment, page 16.
5. Insert safety pin in latch
6. Adjust seat forward/backward with lever below seat.
7. Adjust height of pedals to desired position by
removing/replacing bolts (Y).
8. Loosen two bolts (C) on topside of pedals. Rotate
pedal to desired position. Tighten bolts.
12V Auxiliary Ports
12V auxiliary power ports are provided to power
accessories.
ti11087a
ti10936a
M
NOTICE
12V auxiliary ports must be used to power
accessories. Battery damage can result if other means
are used to power accessories.
ti11086a
ti11085a

Startup
8 3A9034B
Startup
Know Your Controls
Direction/Speed Pedals
The Direction/Speed Pedals drive the LineDriver
forward and in reverse. Switching from forward to
reverse creates a braking action. When both feet are
removed from the pedals, the LineDriver stops. Use one
or both feet to operate the pedals.
Parking/Emergency Brake
The Parking/Emergency Brake stops the machine in an
emergency and prevents it from rolling when parked. To
engage the Parking/Emergency Brake, press brake
pedal firmly until it latches. To release, press the lower
edge of the brake pedal.
Speed Switch
ExactMil™ (Speed Control) Mode
ExactMil Mode ensures a consistent paint thickness by
holding the speed steady. To enable ExactMil mode:
1. Stop moving. Turn speed control knob all the way
counterclockwise.
2. Set Speed Switch to ExactMil position.
3. Depress foot pedal to go forward. Adjust speed
control knob to desired speed setting.
NOTE: ExactMil speed control is only active when
moving forward. Reverse speed is not impacted.
ExactMil speed control limits the maximum speed that
can be obtained with the pedal.
To disable ExactMil Mode:
• Return Speed Switch to center position.
Full Speed Mode
Set Speed Switch to the center position. This
allows a forward speed of 10 mph (16 kph) and a
reverse speed of 7 mph (11 kph).

Startup
3A9034B 9
Incline/ECO Mode
Incline/ECO Mode is the recommended default mode
for all operations. It is helpful when greater control is
needed such as during loading or unloading and in
congested areas. Incline/ECO mode should be used
when operating on inclines. It also extends battery life.
To enable Incline/ECO mode:
• Set Speed Switch to Incline/ECO position.
NOTE: Incline/ECO Mode limits forward speed to 5.5
mph (9 kph) and reverse speed to 4 mph (6 kph).
To disable Incline/ECO Mode:
• Return Speed Switch to center position.
Buzzer
A buzzer will sound to indicate different operating
conditions.
Daily Inspections
Perform the following inspections each day before
using the LineDriver ES Lithium.
1. Check battery charge level. Charge if not fully
charged.
2. Inspect Coupler for excess movement. Adjust if
needed. See Coupler Adjustment, page 16.
Replace Coupler when it is no longer adjustable.
3. Check function of the Seat Interlock Switch. The
Seat Interlock Switch stops the ES Driver when the
operator leaves the seat, and disables the
Direction/Speed Pedals.
a. With the Parking/Emergency Brake ON, move
the Power Switch to the ON position while
standing next to the LineDriver ES.
b. Gently tap the Direction/Speed Pedals. The
LineDriver ES should not attempt to travel.
c. Sit on the seat and gently tap the
Direction/Speed Pedals. The unit should
attempt to travel.
d. Service the Seat Interlock Switch if the
LineDriver does not respond as described in
steps b and c above.
4. Test Parking/Emergency Brake function and
adjustment.
a. Choose a flat open area. Accelerate unit to 3
mph (5 kph).
b. Cause the LineDriver ES to roll freely
(freewheel) by moving the Power Switch to the
OFF position.
c. Stop unit by applying Parking/Emergency
Brake. To adjust brakes, see
Parking/Emergency Brake Adjustment or
Replacement, page 14.
Single tone, about one
second long, after
turning the Power Switch
ON.
Direction/Speed control
pedals now active.
Repeating tone, about
every second.
Batteries are deeply
discharged. See
Charging the Batteries,
page 12.
Continuous tone while
traveling faster than 6.5
mph (10 kph).
Reduced braking available
from Direction/Speed
Pedals. See warning in
Extended Braking
Distance, page 11.

Operation
10 3A9034B
Operation
Differences in Operation
The LineDriver ES Lithium operates differently than a
gasoline powered LineDriver.
1. LineDriver ES rolls freely, especially on inclines,
when the power is off. Set Parking/Emergency
Brake before turning off.
2. Turn power on before releasing Parking/Emergency
Brake.
3. Performance drops when the battery charge
becomes low. When there is about one hour of
runtime remaining, the Voltage Meter begins to
flash. When the batteries are deeply discharged
and the LineDriver ES is about to shut down, the
buzzer sounds about once per second.
4. The response of the Direction/Speed pedals is
softer. Learn this softer response before operating
on a job site.
How to Operate
1. Sit on seat to actuate Seat Interlock Switch. Ensure
Direction/Speed Pedals are not depressed.
2. Turn Power Switch ON. Buzzer will sound in a few
seconds, indicating that the Direction/Speed
Pedals are now active.
3. Disengage Parking/Emergency Brake on LineDriver
and any brakes on attached equipment.
4. Squeeze hand control to release caster wheel of
attached equipment.
NOTE: LineDriver motion is forward and reverse. Turns
are made with the striper or grinder.
5. Push striper or grinder handle bars to begin desired
turn.
6. Move Direction/Speed pedals to drive the
LineDriver, as shown below. Switching from
forward to reverse creates a braking action.
NOTE: LineDriver stops when both feet are removed
from pedals.
ti10937a
FREEWHEEL HAZARD
Turning the Power Switch OFF will result in loss of
drive power. Loss of drive power causes LineDriver to
freewheel, which allows it to roll freely.
• Do not turn Power Switch OFF while LineDriver is
in motion.
• If loss of drive power occurs while LineDriver is in
motion, use the Parking/Emergency Brake to bring
LineDriver to a stop.
• Always engage Parking/Emergency Brake before
turning Power Switch OFF or standing up from
seat.
ti10935a

Operation
3A9034B 11
7. Engage Parking/Emergency Brake when not
operating LineDriver. This prevents rolling when on
an incline.
Operating on Inclines
Extended Braking Distance
Operating on inclines results in extended braking
distances.
1. Select Incline/ECO mode on Speed Switch when
operating on inclines.
2. Be prepared to use the Parking/Emergency Brake
when operating on inclines.
NOTE: Do not operate on inclines greater than 7.5 °
(13%).
Starting and Stopping on an Incline
1. Engage the Parking/Emergency Brake before
turning the Power Switch to OFF when parking on
an incline.
2. Turn the Power Switch to ON, and allow the
machine to initialize before releasing the
Parking/Emergency Brake when starting on an
incline.
Trailer Loading & Unloading
NOTE: LineDriver ES rolls freely, especially on inclines,
when the power is off. Set Parking/Emergency Brake
before turning off. Turn power on before releasing
Parking/Emergency Brake.
1. Always keep LineDriver connected to striper or
grinder.
2. Use a level surface to load and unload. Leave
sufficient space behind ramps.
3. Use loading ramps of sufficient length and capable
of handling weight of unit and operator.
4. Adjust striper or grinder handlebar to highest
position. Slide seat back as far as possible.
5. Use right foot to engage Parking/Emergency Brake.
Use left foot to control speed. Use ECO Mode to
limit speed.
6. Slowly drive straight up/down ramps (do not drive
at an angle).
7. Keep a firm grip on handlebars as the ramp is
negotiated.
NOTE: Striper or grinder handlebars swing up/down as
the ramp is engaged/disengaged. Keep legs clear.
REDUCED BRAKING HAZARD
The braking from the Direction/Speed pedals can be
significantly reduced when going down inclines at
speeds over 6.5 mph (10 kph). This reduced braking
results in longer braking distance than normal, which
could lead to an accident.
A continuous buzzer alarm will sound when this
reduced braking condition occurs. If this alarm
sounds, apply the Parking/Emergency Brake to slow
down. Failure to do so could result in serious injury.
• Do not drive in a manner that causes this alarm to
sound.

Operation
12 3A9034B
Charging the Batteries
The charger may be used any time the LineDriver is not
being used. When the batteries are fully charged, the
charger automatically stops.
Batteries are 50% charged when leaving the factory.
Due to self-discharging of the battery, charge battery
before first use. It takes ~10-12 hours to charge a fully
depleted battery, and ~4 hours to charge the battery
3/4 full.
NOTE: Battery life depends on the depth of discharge
per cycle. A battery that is discharged to 50% depth
will get over twice as many cycles in its life compared
to it being discharged to 100% depth each cycle.
1. Place unit in dry, well-ventilated area and away
from flammable or combustible materials, including
paints and solvents.
2. Position the driver so the wheels are on a true
grounded surface, not on pavement.
3. Ensure Power Switch is in OFF position.
4. Use your smartphone’s camera to scan and
download the Power Sonic Quick Guide and
Battery App to check the battery level.
5. Plug charging cord into charging port on the unit.
Connect an extension cord, per charger manual, to
the charging cord and plug it into wall power.
6. Always unplug the battery charger when the
batteries reach full charge.
Always use an outlet that is properly installed and
grounded in accordance with all local codes and
ordinances.
Do not modify the plug provided; if it does not fit the
outlet, have the proper outlet installed by a qualified
electrician.
Power Requirements
• All models use the same battery charger. Refer to
Technical Specifications, page 37, for power
requirements.
Battery Maintenance
• Charging – always unplug charger after 24 hours.
• Storage – never leave the battery charger plugged
into wall power during storage. For optimal battery
life, don’t allow battery to get below 20% SOC
(state of charge).
• In long-term storage applications, a lithium battery
should not be stored at 100% SOC. Store between
30-70% SOC.
• Recommended long-term storage temperature: 59°
to 95°F (15° to 35°C).
Replace and charge battery only in well-ventilated
area and away from flammable or combustible
materials, including paints and solvents. The charger
may become hot while charging. Do not touch. Refer
to Charger Manual for additional information. This equipment must be grounded to reduce the risk
of static sparking and electric shock. An electric
shock or static spark can cause fumes to ignite or
explode. An improper ground can cause electric
shock. A good ground provides an escape wire for
the electric current.

Operation
3A9034B 13
7. The Charging Output Indicator means that the
charger output is active.
8. When power is connected, charger will immediately
begin charging.
NOTE: Battery will charge to ~30 volts while charging
and then it will come back down to ~27 volts after fully
charging.
NOTE: The Charge Display may show codes to indicate
different conditions. Refer to charger manual for
additional information.
• ‘F’ codes meaning that an internal fault condition
has caused charging to stop.
• ‘E’ codes meaning that an external error condition
has caused charging to stop.
9. When battery charge indicator is solid green, the
charge is complete.
DISPLAY
CHARGING
OUTPUT
INICATOR
USB PORT
STATE OF
CHARGE
INDICATOR
FAULT
INDICATOR
ti35137a

Maintenance
14 3A9034B
Maintenance
Parking/Emergency Brake
Adjustment or Replacement
1. Block tires so LineDriver will not move. Release
Parking/Emergency Brake.
2. Ensure Power Switch is in OFF position.
3. Inflate tires to operating pressure per tire sidewall.
Remove two bolts securing brake rod.
4. Select a hole pattern that positions the brake rod
1/8 to 1/4 in. from the tire.
5. Install two bolts and secure brake rod. Repeat for
second tire.
NOTE: Brake rods are not interchangeable from side to
side. Model shown in the graphic above is the right side
version.

Maintenance
3A9034B 15
Throttle Linkage Adjustment

Maintenance
16 3A9034B
Coupler Adjustment
A Coupler too tight or too loose needs to be adjusted.
Before adjusting, check ball and Coupler for wear.
Replace entire Coupler if unable to tighten it.
Ensure Power Switch is in OFF position.

Maintenance
3A9034B 17
Accelerator Calibration (Using Kit 25N880)
1. Turn power OFF. Engage Parking/Emergency
Brake.
2. Slowly raise hitch Coupler until LineDriver rests on
rear bumper.
3. Remove accelerator from LineDriver.
4. Connect calibration cable per illustration. Use a
Digital Multi-Meter to measure volts DC.
5. Mount accelerator to calibration plate and plate to
pedal. This makes it easier to torque fasteners.
6. Ensure nothing is on the operator’s seat so the Seat
Interlock Switch prevents wheel movement. Turn
power ON.
7. Loosen adjustment fastener and set neutral
position voltage to 2.45 ± .05 volts. Use calibration
plate to hold accelerator in this position. Torque
adjustment fastener to 90-100 in-lbs.
8. Rotate accelerator arm back and forth, then return
it to neutral position. Re-adjust voltage if
necessary. Turn power OFF.
9. Install accelerator onto LineDriver. When
connecting linkage, adjust tie rod end so no
pressure is needed to align parts. Otherwise the
LineDriver will creep.
10. LineDriver may creep forward or reverse when
turned on. As a precaution, jack unit up and use
jack stands to support it (two under the frame in the
rear and one under the Coupler).
11. Connect the LineDriver to a striper or grinder, sit on
the seat and turn on. If wheels do not turn (with no
pressure on speed pedals), calibration is complete.
If they do turn, follow Throttle Linkage
Adjustment, page 15.

Maintenance
18 3A9034B
Transaxle Service
Check Oil Level (Annually)
1. Turn power OFF. Engage Parking/Emergency
Brake.
2. Slowly raise hitch Coupler until LineDriver rests on
rear bumper.
3. Remove fill plug from transaxle cover.
4. Slowly lower hitch Coupler. Oil will begin to flow out
of transaxle when hitch Coupler is lowered to 10.5 -
12.5” from the floor. Add or remove oil as needed.
5. Reinstall plug.
Change Oil (recommended every 3 years)
1. Turn power OFF. Engage Parking/Emergency
Brake.
2. Slowly raise hitch Coupler until LineDriver rests on
rear bumper.
3. Place pan under transaxle cover. Remove screws
and cover.
NOTE: Sealant may hold cover on. If necessary, pry
cover off.
4. Allow oil to drain completely. Follow local
ordinances and regulations for disposal.
5. Clean cover and housing where sealant is used.
Apply new sealant (recommended is RTV silicone).
6. Reinstall cover with screws.
7. Remove drain plug. Fill with 22 oz. of Mobilfluid™
424.
8. Check oil level per above. Reinstall plug.
9. Check for oil leaks. Fix if necessary.

Repair
3A9034B 19
Repair
Battery Pack Replacement
NOTE: Prior to replacing batteries, refer
toTroubleshooting - LineDriver, page 22, to
determine if the batteries are the cause of the problem.
Never mix battery types or brands. A new battery can
be mixed with older batteries. The LineDriver ES ships
with three lithium batteries, however, a fourth battery
can be added for additional run time between charge.
1. Turn Power Switch OFF. Turn lights OFF.
Disconnect 12V accessories. Unplug the battery
charging cord.
2. Remove Tool Tray.
3. Remove rear screws of Seat Lid.
4. Pivot Operator Seat forward slowly.
5. Remove battery cables. Always disconnect
negative (black) cables prior to disconnecting
positive (red) cables.
6. Remove batteries and recycle according to below.
7. Install new batteries. Install cables positive to
positive and negative to negative. To prevent
battery terminal short circuit, always connect the
positive (red) cables prior to connecting negative
(black) cables.
8. Reinstall seat and Tool Tray.
9. Charge batteries. See Charging the Batteries , page
12.

Repair
20 3A9034B
Transaxle Replacement
1. Turn power OFF.
2. Remove rear screws of Seat Lid. Pivot seat forward
slowly.
3. Disconnect battery cables to motor controller.
4. Jack unit up and use jack stands to support unit
(two jacks at the rear and one jack in the front).
Raise wheels about 2 inches off the floor, leaving
enough room to pull the transaxle out.
5. Remove wheels.
6. Remove motor cover.
7. Disconnect wires attached to motor.
8. Place a support under motor and remove transaxle.
9. Place new transaxle under unit. Lay motor wires on
transaxle.
10. Bolt new transaxle to frame.
11. Connect wires to motor. Take care when attaching
the three large cables to prevent damage to the
plastic terminal block on the motor.
12. Install motor cover.
13. Install wheels.
14. Lower unit to the floor and reconnect the battery
cables.
15. Reinstall Operator Seat.
Traction Motor Replacement
Follow Transaxle Replacement, page 20.
Motor Controller Replacement
1. Turn power OFF.
2. Remove rear screws of Seat Lid. Pivot seat forward
slowly.
3. Disconnect battery cables to motor controller. Tape
over terminals to prevent accidental contact.
4. Remove Seat Cover to expose motor controller.
5. Disconnect wires from motor controller.
6. Remove nuts holding motor controller in place.
7. Install new motor controller.
8. Connect wires to new motor controller. Be sure 35
pin connector latches.
9. Install Seat Cover.
10. Reconnect battery cables. Pivot seat back and
reinstall rear screws of Seat Lid.
11. LineDriver may creep forward or reverse when
turned on. As a precaution, jack unit up and use
jack stands to support it (two under the frame in the
rear and one under the Coupler).
12. Sit on the seat and turn on. If wheels turn with no
pressure on speed pedals, follow the Accelerator
Calibration Procedure, page 17.