Graco 3A7600A, GrindLazer, Models 25P474, 25P475, 25P476, 25P783 Owner's Manual

Operation, Repair, Parts
GrindLazer™
3A7600A
EN
For removal of materials from flat horizontal concrete and asphalt surfaces. Not approved for
use in explosive atmospheres or hazardous (classified) locations. Gas/propane units not for
use indoors or in enclosed spaces. For professional use only.
Models 25P474 / 25R100 - Graco DC1538 G DCS (High speed / Standard speed)
Models 25P475 / 25R101 - Graco DC1525 P DCS (High speed / Standard speed)
Models 25P476 / 25R102 - Graco DC1520 E DCS 480V (High speed / Standard speed)
Models 25P783 / 25R103 - Graco DC1520 E DCS 380V (High speed / Standard speed)
Maximum Working Pressure: 1750 psi (121 bar, 12.1 MPa)
Important Safety Instructions
Read all warnings and instructions in this manual and in the Kohler engine manual before
using the equipment. Be familiar with the controls and the proper usage of the equipment.
Save these instructions.
Related Manuals:
62 590 13 - Kohler Owner’s Manual (Gas)
DC1538 G DCS
24 590 52- Kohler Owner’s Manual (Propane)
DC1525 P DCS
(Drums and cutters sold separately)
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www.graco.com/techsupport
DC1520 E DCS
Contents
Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Gasoline/Propane Engine Warnings . . . . . . . . . . . . . . . 5
Electric Motor Warnings . . . . . . . . . . . . . . . . . . . . . . . . 6
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . 7
DC1538 G DCS (Gas) . . . . . . . . . . . . . . . . . . . . . . . . . 7
DC1525 P DCS (Propane) . . . . . . . . . . . . . . . . . . . . . . 8
DC1520 E DCS (Electric) . . . . . . . . . . . . . . . . . . . . . . . 9
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Propane Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Lifting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Handlebar Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 11
Engine Kill Button (Gas/Propane) . . . . . . . . . . . . . . . . 11
Drum Installation/Replacement . . . . . . . . . . . . . . . . . . 12
DCS Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Machine Start Up (Gas & Propane) . . . . . . . . . . . . . . 17
Machine Start Up (Electric) . . . . . . . . . . . . . . . . . . . . . 17
When operating... . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Hydrostatic Drive Operation . . . . . . . . . . . . . . . . . . . . 18
DCS Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . 21
Hydraulic Belt Replacement (Electric Models only) . . 22
Bearing Housing Replacement . . . . . . . . . . . . . . . . . . 23
Drive Pulley Replacement . . . . . . . . . . . . . . . . . . . . . . 24
Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Gas/Propane Models only . . . . . . . . . . . . . . . . . . . . . . 25
All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Purge Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Front Wheel Adjustment . . . . . . . . . . . . . . . . . . . . . . . 26
Recycling and Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Rechargeable Battery Disposal . . . . . . . . . . . . . . . . . 27
End of Product Life . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DCS Control Translations . . . . . . . . . . . . . . . . . . . . . . . . 28
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DCS Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DCS Actuator Rod Does Not Move . . . . . . . . . . . . . . . 33
Parts - Main Housing Assembly (All Models) . . . . . . . . 34
Parts List - Main Housing Assembly (All Models) . . . . 35
Parts - Front Wheel / Wheel Carrier Assemblies (All Models)
36
Parts List - Front Wheel / Wheel Carrier Assemblies (All
Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2
Parts - Guidebar / Vacuum Assemblies (All Models) . . 38
Parts List - Guidebar / Vacuum Hose Assemblies (All
Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Parts - Hydraulic Motor / Rear Assembly (All Models) . 40
Parts List - Hydraulic Motor / Rear Assembly (All Models)
41
Parts - Support System / Hydraulic Tank (All Models) . 42
Parts List - Support System / Hydraulic Tank (All Models)
43
Parts - Motor / Hydraulic Assemblies (Gas) . . . . . . . . . 44
Parts List - Motor / Hydraulic Assemblies (Gas) . . . . . 45
Parts - Hydraulic Fittings / Fuel Tank Assemblies (Gas) 46
Parts List - Hydraulic Fittings / Fuel Tank Assemblies (Gas)
47
Parts - Pulley Assemblies (Gas) . . . . . . . . . . . . . . . . . . . 48
Parts List - Pulley Assemblies (Gas) . . . . . . . . . . . . . 49
Parts - Dashboard / Battery Assemblies (Gas) . . . . . . . 50
Parts List - Dashboard / Battery Assemblies (Gas) . . 51
Parts - Motor / Hydraulic Assemblies (Propane) . . . . . . 52
Parts List - Motor / Hydraulic Assemblies (Propane) . 53
Parts - Propane Tank / Dashboard Assemblies (Propane)
54
Parts List - Propane Tank / Dashboard Assemblies
(Propane) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Parts - Pulley Assemblies (Propane) . . . . . . . . . . . . . . . 56
Parts List - Pulley Assemblies (Propane) . . . . . . . . . . 57
Parts - Battery Assembly (Propane) . . . . . . . . . . . . . . . . 58
Parts List - Battery Assembly (Propane) . . . . . . . . . . . 59
Parts - Electrical Components (Electric) . . . . . . . . . . . . 60
Parts List - Electrical Components (Electric) . . . . . . . 61
Parts - Hydraulic Motor Assemblies (Electric) . . . . . . . 62
Parts List - Hydraulic Motor Assemblies (Electric) . . . 63
Parts - Hydraulic Assembly (Electric) . . . . . . . . . . . . . . 64
Parts List - Hydraulic Tank Assembly (Electric) . . . . . 65
Parts - Pulley Assemblies (Electric - 480V & 380V) . . . 66
Parts List - Pulley Assemblies (Electric 480V & 380V) 67
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Gas Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Propane Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Electric Models (480V) . . . . . . . . . . . . . . . . . . . . . . . . 70
Electric Models (380V) . . . . . . . . . . . . . . . . . . . . . . . . 71
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . 74
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3A7600A
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation
point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these
symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard
symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
WARNING
DUST AND DEBRIS HAZARD
Grinding concrete and other surfaces with this equipment can create dust that contains hazardous
substances. Grinding can also create flying debris.
To reduce the risk of serious injury:
• Control the dust to meet all applicable workplace regulations.
• Wear protective eye wear and a properly fit-tested and government approved respirator suitable for
the dust conditions.
• Use equipment only in a well-ventilated area.
• Grinding equipment must be used only by trained personnel who understand the applicable workplace regulations.
ENTANGLEMENT AND MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Do not wear loose clothing, jewelry or long hair while operating equipment.
• Before checking, moving, or servicing equipment, disable power. For gas/propane units, disconnect
negative (-) battery cable. For electric units, unplug power cord.
BURN HAZARD
Cutters and engine can become very hot during operation. To avoid severe burns, do not touch hot
equipment. Wait until equipment has cooled completely.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of dust or
chemicals, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eye wear.
• Protective shoes.
• Gloves.
• Hearing protection.
• Properly fit-tested and government approved respirator suitable for the dust conditions.
3A7600A
3
Warnings
WARNING
SKIN INJECTION HAZARD
High-pressure fluid from 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.
•
•
•
•
•
•
•
•
Inspect hose before each use for cuts, bulges, kinks or any other damage.
Replace damaged hose immediately.
Replace hoses proactively at regular intervals based on your operating conditions.
Tighten all fluid connections before operating the equipment.
Keep clear of leaks.
Do not stop or deflect leaks with your hand, body, glove, or rag.
Never exceed hose Maximum Pressure or Temperature ratings.
Only use chemicals that are compatible with hose materials. See Technical Specifications in this
manual. Read Safety Data Sheets (SDSs) and fluid and solvent manufacturer’s recommendations.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not leave the work area while equipment is energized. Turn off all equipment when equipment
is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
• Do not alter or modify equipment.
• 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.
• Maintain a safe operating distance from other people in the work area.
• Avoid any pipes, columns, openings, or any other objects protruding from work surface.
4
3A7600A
Warnings
Gasoline/Propane Engine Warnings
WARNING
FIRE AND EXPLOSION HAZARD -- GASOLINE
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:
• Use equipment only outdoors. Never use indoors or in enclosed spaces.
• 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.
• Eliminate all ignition sources, such as pilot lights, cigarettes, and portable electric lamps.
• Keep work area free of debris, including solvent, rags and gasoline.
• Keep a fire extinguisher in work area.
FIRE AND EXPLOSION HAZARD -- PROPANE (LP GAS)
Propane is highly flammable and explosive. To help prevent fire and explosion:
• Use equipment only outdoors. Never use indoors or in enclosed spaces.
• Eliminate all ignition sources, such as pilot lights, cigarettes, and portable electric lamps.
• If you smell propane, shut off the machine immediately and close the propane tank fuel valve. Do not
use machine until you identify and correct the problem.
• Always turn off propane tank fuel valve when equipment is not in use.
• Do not store propane tanks, or equipment with a propane tank, inside a building or enclosed area.
• Keep a fire extinguisher in work area.
CARBON MONOXIDE HAZARD
Exhaust contains poisonous carbon monoxide, which is colorless and odorless. Breathing carbon
monoxide can cause death.
• Operate engine only outdoors. Never use indoors or in enclosed spaces.
BATTERY HAZARD
Lead-acid batteries produce explosive gases and contain sulfuric acid that can cause severe burns. To
avoid sparks and injury when handling or working with a lead-acid battery:
• Read and follow the battery manufacturer’s warnings.
• Exercise caution when working with metallic tools or conductors to prevent short circuits and sparks.
• Keep all sparks, flames, and cigarettes away from batteries.
• Always wear protective eyewear and protective equipment for face, hands, and body.
• If you have direct contact with battery fluid, flush with water and consult a physician immediately.
• Installation and maintenance must be performed by knowledgeable personnel only.
3A7600A
5
Warnings
Electric Motor Warnings
DANGER
SEVERE ELECTRIC SHOCK HAZARD
This equipment is powered by more than 240 V. Contact with this voltage will cause death or serious
injury.
•
•
•
•
•
•
Turn off and disconnect power cord before servicing equipment.
Connect only to grounded electrical outlets.
Use only 4-wire extension cords.
Ensure ground prongs are intact on power and extension cords.
Do not expose to rain. Store indoors.
All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
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 regulations.
•
•
Improper installation of the grounding plug is able to result in a risk of electric shock.
This product is for use on a nominal 480 V or 380 V circuit and has a grounding plug similar to the
plugs illustrated in the figure below.
480 V
•
•
•
•
•
•
380 V
Only connect the product to an outlet having the same configuration as the plug.
Do not modify the plug provided; if it does not fit the outlet, have the proper outlet installed by a qualified electrician.
Do not use an adapter with this product.
When repair or replacement of the cord or plug is required, only connect the grounding wire to the
extended ground blade or pin.
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.
Extension Cords:
•
•
•
6
Use only a 4-wire extension cord that has a grounding plug and a grounding receptacle that accepts
the plug on the product.
Make sure your extension cord is not damaged. If an extension cord is necessary, use 10 AWG
(6.0 mm2) minimum to carry the current that the product draws.
An undersized cord results in a drop in line voltage and loss of power and overheating.
3A7600A
Component Identification
Component Identification
DC1538 G DCS (Gas)
See Lifting
Instructions,
page 10.
Component
Component
A
Adjustable Handlebar
M
Engine Kill Button
B
Handlebar Adjustable Bolts
N
Manual Height Adjustment
C
DCS Control
O
Battery
D
Hour Meter / Tachometer
P
Vacuum Port
E
Home Button
Q
Lift Carriage with Swivel Casters
F
Zero Button
R
Self-Propelled Drive Wheels
G
Cut Depth Button
S
Removable Side Plate
H
Up / Down Button
T
Air Intake / Filtration System
I
DCS Power Switch
U
Hydraulic Drive Pump
J
Key Switch
V
Hydraulic Reservoir
K
Throttle Control
W
Engine (Kohler)
L
Forward / Reverse Control Lever
X
Gas Tank
3A7600A
7
Component Identification
DC1525 P DCS (Propane)
See Lifting
Instructions,
page 10.
Component
Component
8
A
Adjustable Handlebar
M
Engine Kill Button
B
Handlebar Adjustment Bolts
N
Manual Height Adjustment
C
DCS Control
O
Battery
D
Hour Meter / Tachometer
P
Vacuum Port
E
Home Button
Q
Lift Carriage with Swivel Casters
F
Zero Button
R
Self-Propelled Drive Wheels
G
Cut Depth Button
S
Removable Side Plate
H
Up / Down Button
T
Air Intake / Filtration System
I
DCS Power Switch
U
Hydraulic Drive Pump
J
Key Switch
V
Hydraulic Reservoir
K
Throttle Control
W
Engine (Kohler)
L
Forward / Reverse Control Lever
X
Propane Tank Bracket
3A7600A
Component Identification
DC1520 E DCS (Electric)
See Lifting
Instructions,
page 10.
Component
Component
A
Adjustable Handlebar
J
Manual Height Adjustment
B
Handlebar Adjustment Bolts
K
Vacuum Port
C
DCS Control
L
Lift Carriage with Swivel Casters
D
Home Button
M
Self-Propelled Drive Wheels
E
Zero Button
N
Removable Side Plate
F
Cut Depth Button
O
Hydraulic Drive Pump
G
Up / Down Button
P
Hydraulic Reservoir
H
Motor Start Switch
Q
Electric Motor
I
Forward / Reverse Control Lever
R
Power Plug
3A7600A
9
Setup
Setup
Propane Tank
Lifting Instructions
Propane (LP gas) supply tank not provided by Graco.
Supply tank must be vertically mounted and vapor
withdrawal type. Supply tank must be designed,
fabricated, and marked in accordance with specifications
and regulations for LP-Gas cylinders at: The U.S.
Department of Transportation (DOT); the National
Standard of Canada, CAN/CSA-B339, Cylinders,
Spheres, and Tubes for Transportation of Dangerous
Goods; the Transportable Pressure Vessels Regulations
2001 (S1 2001/1426); or the Gas Cylinders (Pattern
Approval) Regulations 1987 (SI 1987/116)(Pattern
Approval Regulations) for EEC-type cylinders under
European Directive 84/525/EEC, 84/526/EEC, and
84/527/EEC.
•
Only lift the equipment using all available lift points.
The lift chains must be angled at least 45° from the
horizontal.
•
Lift the system with a lift apparatus rated
appropriately for the weight of the system. See
Technical Data, page 72.
•
Lift the system using the lift eyes shown on the
appropriate illustration.
Check gas supply hose connection to propane cylinder.
Make sure fitting is free of debris before connecting to
tank. Make sure gas connection is screwed completely
on and is free of leaks.
NOTE: The propane tank connection hose is equipped
with a POL gas fitting. If a different sized fitting is
needed, see your local LP gas equipment supplier.
10
3A7600A
Setup
Handlebar Adjustment
Engine Kill Button (Gas/Propane)
The handlebars are equipped with a high-density
vibration suppression material to reduce operator
fatigue. To adjust the handlebars to a new position for
different height operators, please follow these steps:
In the event of a malfunction or an accident (such as the
machine operator falling or losing footing), the
GrindLazer is equipped with a corded Engine Kill Button.
Attach the end of the cord to the operator’s belt or wrist,
and snap the clip into place on the button by raising the
top of the Engine Kill Button and inserting the clip into the
gap. If the operator becomes distanced too far from the
machine, the cord will detach from the button and the
machine will stop running. The engine can also be
stopped by pressing down on the Engine Kill Button.
1. Using a 9/16” wrench or socket, loosen the bolts on
both sides of the handlebars until the handlebar
moves freely.
2. Stand behind the machine and lightly tap the
handlebar to the desired position.
3. Re-tighten the bolts to 260-300 in-lb (29-34 N•m) to
lock the handlebars into position.
NOTE: Never operate equipment with loose
handlebars. The bolts must be fastened tightly to
ensure the handle is locked into position.
3A7600A
11
Setup
Drum Installation/Replacement
4. Remove six hex head cap screws from the Side
Plate using the 9/16” socket or wrench.
5. Remove the Side Plate (this may require the rubber
mallet to break it loose).
Gas/Propane: To avoid injury from unexpected start
up, turn ignition OFF, remove key, and disconnect
spark plug wires before you service your unit.
Electric: To avoid injury from unexpected start up,
disconnect power plug before you service your
machine.
6. Slide out the drum assembly. Use caution as the
assembly is heavy.
Normal use will require periodic drum inspection and
may necessitate drum replacement. Time of
replacement will vary according to usage and load
factors.
Tools needed:
•
9/16” socket or wrench
•
Rubber mallet
•
1-1/8” wrench
1. Turn DCS Power Switch ON. Wait until the
GrindLazer cools off if it has been running.
2. Press Home Button on DCS Control to raise the
cutter drum off the work surface.
7. Before replacing the drum onto hex shaft:
a. Check that all bearings are in good working
order.
Once at home position, disconnect negative (-)
battery cable for gas/propane units. For electric units,
disconnect power plug. If more adjustment is needed
at this point, use the Manual Height Adjustment,
page 20.
3. Using 1-1/8” and 9/16” wrench, lower jam nuts and
support bolts on engine/motor plate so that tension
is released off belt.
b. Remove dirt and material build-up from inside
main housing and drum.
c.
Apply grease to all metal contacts.
d. Check drum spacers for wear, replace if
necessary (if applicable).
8. Align and slide drum back onto the hex shaft.
9. Replace Side Plate (slide onto) hex shaft and
reinstall the six cap screws and torque to 40 ft/lbs
(54.2 N•m). Check that drum moves side to side and
drum spacers are free to move (if applicable).
10. To tension the belt, turn the base plate pivot nut with
the 1-1/8” wrench. This will raise the engine/motor
base plate. Use the 9/16” wrench to raise bolts into
place, locking jam nut when complete.
NOTE: An extra drum loaded with cutters for rapid
job site replacement is recommended.
12
3A7600A
Setup
DCS Control
Buttons on the DCS Control have two functions, quick
press and long press. Quick press refers to pressing the
button and releasing the button quickly, while long press
is pressing the button and holding the button for two or
more seconds.
Zero Button
Quick Press: Takes the drum to the work surface.
NOTE: “+” (plus) refers to above work surface. “-”
(minus) refers to below work surface.
Run Screen
DEPTH ..... +0.21"
TARGET .... --0.08"
Current Drum
Position
Saved Cut Depth
UP BUTTON
DOWN BUTTON
HOME
BUTTON
ZERO
BUTTON
CUT DEPTH
BUTTON
Long Press: Reprograms the zero point to the current
drum position.
ti35660a
Home Button
Quick Press: Takes the drum to its highest position.
Long Press: Brings up Menu Screen.
3A7600A
13
Setup
Cut Depth Button
Quick Press: Takes the drum to the Cut Depth Target.
Up Arrow Button*
Quick Press: Raises the drum by 0.01” (0.25mm, 10
mil).
Long Press: Raises the drum to Home position.
Long Press:
-
If at or above zero point: Opens new screen to
select desired cut depth using up/down buttons.
•
To exit without saving, quick press the Cut
Depth Button.
•
To exit with saving, long press the Cut Depth
Button.
-
If below zero point: Reprograms the Cut Depth
Target to the current drum position.
Down Arrow Button*
Quick Press: Lowers the drum by 0.01” (25mm, 10
mil).
Long Press: Lowers the drum to Cut Depth Target.
* Handlebar Rocker Switch has the same functions as
Up and Down Arrow Buttons.
14
3A7600A
Setup
Menu Screens
To display the Menu Screens, hold down Home Button
from the Run Screen. To save menu settings and return
to Run Screen, hold down Home Button from any Menu
Screen.
Menu Screen #3 - Model Select
Your GrindLazer model name can be found on the handlebar dashboard label. Select the model on the DCS
Control which matches the model you have. This ensures
accurate depth readings. Hold down Up or Down Arrow
Buttons to cycle through models.
To cycle through selections in each Menu Screen, use
Up and Down Arrow Buttons.
To advance to next Menu Screen, quick press the Home
Button.
Menu Screen #1 - Language
Select your desired language (English, Spanish, French,
German, or International Symbols).
Menu Screen #4 - Software revision
Displays the revision of the software on the DCS Control.
Menu Screen #2 - Units
Select your desired depth units (inches, millimeters, or
mils).
3A7600A
15
Setup
Menu Screen #5 - Error Codes
Displays the most recent error code and the total number of times that error has occurred. Cycle through previous error codes using Up/Down Buttons.
Error Codes
E04: High Voltage
E05: High Motor Current
E08: Low Voltage
E09: Hall Sensor Error
E12: High Current (short circuit)
E31: Home Button Error
E32: Zero Button Error
E33: Cut Depth Button Error
E34: Up Button Error
E35: Down Button Error
To clear an error code that appears while on the Run
Screen:
1. Turn DCS Power Switch OFF.
2. Address/Fix the issue.
3. Turn DCS Power Switch ON.
NOTE: See Repair Manual for more information on
Error Codes and Troubleshooting.
16
3A7600A
Operation
Operation
If the Engine Does Not Start
•
Turn the ON/OFF Switch on the Control Panel to ON.
•
Check engine for proper gas and oil levels.
•
Do not start machine while cutter head is in contact
with the work surface. Doing so can cause the
operator to lose control of the machine, resulting in
property damage and/or personal injury.
Check the spark plug. Make sure socket areas are
clean and clear of debris, and the proper gap is set.
Replace if needed.
•
Check the corded Engine Kill Button’s connections.
Make sure the corded safety stop “C” connector is
properly inserted into the Engine Kill Button.
Electric: To avoid injury from unexpected movement,
ensure Power Switch is in the OFF position before
connecting or disconnecting the power cord. In the
event of a power failure or interruption, ensure Power
Switch is in the OFF position before restoring power.
Machine Start Up (Electric)
NOTICE
Make sure motor is rotating in the correct direction.
Look for clockwise rotation on the right side of the
machine at drum end shaft by turning on and off
quickly. Incorrect rotation will damage hydraulic pump
and could damage cutters if contact is made with the
work surface. If rotation is incorrect, exchange positions of two power wires at the plug. Do not loosen or
move the ground wire at the plug.
Machine Start Up (Gas &
Propane)
1. Turn DCS Power Switch ON.
2. Verify the Forward/Reverse Control Lever is in the
neutral (N) position.
3. Place the throttle control at the idle position.
1. Turn motor ON/OFF switch to OFF.
2. Verify the Forward/Reverse Control Lever is in the
neutral (N) position.
3. Plug the machine in to the electrical source.
4. Turn motor ON/OFF switch to ON.
5. Move throttle control to open or run position when
engine is warmed up.
5. Before operating, run the drum with the cutters not
touching the work surface. If there is excessive
vibration, re-balance the cutter setup, check bearing
condition, and/or make sure the drive shaft is
secured.
6. Increase throttle to optimal machine operating
position.
If the Motor Does Not Start
4. Start the engine.
NOTE: Engine speed for all drum assemblies is
3450 RPM.
7. Before removal, run the drum with the cutters not
touching the work surface. If there is excessive
vibration, re-balance the cutter setup, check bearing
condition, and/or make sure the drive shaft is
secured.
3A7600A
•
Make sure the motor is plugged into the electrical
source.
•
Turn motor ON/OFF switch to ON.
17
Operation
When operating...
Hydrostatic Drive Operation
Engine/motor must be warmed up and at desired speed.
SEVERE ELECTRIC SHOCK HAZARD
Electric: Keep the extension cord clear of machine
travel path.
Adjust the height of the cutter drum. Set the depth of cut
to allow the cutters to go through only the materials to be
removed. Make certain that the drum is positioned to
where only the cutters strike the work surface, and that
the drum assembly never comes in to contact with the
work surface. The cutter tips alone should strike the
work surface (1/8” to 1/4” maximum depth per removal
pass on new cutters). The drum will not survive work
surface contact.
Verify the Forward/Reverse Control Lever is in the
neutral (N) position. Lower the unit to raise the carriage
wheels off the work surface and set the unit onto the
drive wheels. The Forward/Reverse Control Lever
should be in the neutral (N) position and the wheels
should not be turning. At this point the unit can be
propelled forward or reverse by pressing down on the
Control Lever and moving the Control Lever either
forward or backward.
NOTICE
Cutting too deep will cause premature wear to cutters, shafts, drum and other components.
Remove materials in several passes rather than one
deep pass. Several tests will show the best, most
appropriate cutter depth. Use a forward/backward
pattern to achieve your desired finish.
When the job is complete, or the operator wants to cease
work, raise the drum above the work surface by pressing
home button on DCS control.
•
For gas units, stop the machine with the key switch
or power switch.
•
For propane units, stop machine with the key
switch or power switch, then close the propane
supply valve.
•
For electric units, stop machine by turning motor
power switch OFF, and unplug the machine from
the electrical source.
The “live” axle will help move the unit in a straight line.
However, keep both hands on the handle for safe
operation and minor directional corrections.
The drum assembly must be removed daily and
inspected for drum wear, hole elongation and possible
weld separation. Replace the cutter shafts every 40
hours, or prior to any drum wear. If the drum’s center
holes are elongated, order another Graco cutter drum.
18
3A7600A
Operation
DCS Instructions
Each time the DCS Control is turned on, the DCS actuator will travel to the Home position.
Set Cut Depth Target:
Quick press the Zero Button to take the drum to the work
surface. Set the Cut Depth Target by:
1. Quick pressing the Down Arrow Button as many
times as needed to achieve your target. Then long
press the Cut Depth Button to save your target.
NOTE: This method will lower the cutting drum into
the work surface as you set your cut depth.
OR
Once the DCS Control finds Home, ensure the correct
model is selected as well as your desired language and
units. See Menu Screens, page 15, for instructions on
changing these settings.
2. From the Zero Point, long press the Cut Depth Button until a new screen pops up. Use the Down Arrow
Button to enter your Cut Depth Target. Then long
press the Cut Depth Button to save your target and
return to the Run Screen.
NOTE: This method will keep the cutting drum stationary as you set your Cut Depth Target.
Set Zero Point:
With the engine/motor on, lower the drum by pressing
the Down Arrow Button until you hear the cutters make
contact with the work surface. Hold down the Zero Button for 2 seconds. Your Zero Point has now been saved.
NOTE: The Cut Depth Target is based off of the Zero
Point. Re-program the Zero Point if the drum is changed
or worn.
3A7600A
19
Operation
The DCS Control is now ready to grind/scarify.
NOTE: The Zero Point and Cut Depth are referenced
from the Home position. Recalibrate your DCS Control
periodically by pressing the Home button.
NOTE: Pressing any button while the drum is moving to
Zero or Cut Depth will stop the command and halt the
drum from moving any further up or down until another
button is pressed.
Manual Height Adjustment
If the DCS Control is not usable (dead battery, etc.), the
drum height can be adjusted using the Manual Height
Adjustment feature.
3. Insert 6mm hex key into the port the screw plug was
removed from.
•
One revolution of the hex key results in 1/16” (1.6
mm, 62.5 mil) of adjustment at the cutter drum.
•
Rotate counterclockwise to raise the drum; rotate
clockwise to lower the drum.
NOTICE
Max rotation speed is one revolution per second. Do
not use power tools in the Manual Height Adjustment
port. Doing so will cause damage to the actuator.
1. Remove fuse from fuse holder near positive battery
terminal. This will protect the battery from damage.
2. Use a 6mm hex key to remove the screw plug on
the top of the linear actuator.
4. Once the desired depth is achieved, replace the
screw plug in order to keep water and dust out.
20
3A7600A
Repair
Repair
3. Clean the exterior of the machine so you can locate
all of the appropriate parts.
Gas/Propane: To avoid injury from unexpected start
up, disable engine as follows: 1) Turn DCS Power
Switch OFF. 2) Turn ignition OFF. 3) Disconnect
spark plug wires. 4) Disconnect negative (-) battery
cable from battery.
Electric: To avoid injury from unexpected start up,
disconnect power plug before you service your
machine.
4. Using a 9/16” socket or wrench, remove the four hex
bolts attaching the belt cover to the side of the
machine. Remove the cover and set aside.
Electric: To avoid injury from unexpected movement,
ensure Power Switch is in the OFF position before
connecting or disconnecting the power cord.
Drive Belt Replacement
Normal wear will require periodic belt tensioning and
replacement. Time of replacement will vary according to
usage and belt load factors.
5. Turn the lower base plate pivot nuts clockwise with
the 1-1/8” wrench to lower the engine/motor base
plate. Use 9/16” wrench to lower the two bolts on
either side and loosen the drive belt. Remove or
replace the belt as needed.
Tools needed:
•
9/16” socket or wrench
•
1-1/8” open box wrench
•
Straight edge or ruler
1. Wait until the GrindLazer cools off if it has been
running.
2. Make sure the Removable Side Plate is installed.
This ensures the drive ends are in proper position for
servicing.
6. To tension the belt, turn the base plate pivot nut with
the 1-1/8” wrench. This will raise the engine/motor
base plate. Use the 9/16” wrench to raise bolts into
place, locking jam nut when complete.
NOTICE
Ensure belts are aligned using straight edge or ruler
prior to operation. Do not over-tighten the belt as this
will cause premature wear to the belt.
3A7600A
21
Repair
7. Put the belt cover back in place and secure the four
hex nuts with the 9/16” socket or wrench.
\
Unit
Deflection
Force
Deflection
Distance
Electric
11 lbs
1/4”
Gas
16 lbs
1/4”
Propane
12 lbs
1/4”
4. To tighten the belt, slide the bracket up and lightly
tighten the hex bolts. To ensure alignment of the
pulleys, use a ruler or a straight edge and place it on
the faces of both pulleys and adjust the bracket
accordingly. Verify alignment from the front of the
machine. Once properly aligned, tighten the bolts.
Hydraulic Belt Replacement
(Electric Models only)
Normal wear will require periodic belt tensioning and
replacement. Time of replacement will vary according to
usage and load factors.
Tools needed:
•
9/16” socket or wrench
•
Straight edge or ruler
5. Follow instructions on previous page to attach belt
cover, drive belt, and drive pulley.
1. Wait until the GrindLazer cools off if it has been
running.
2. Follow instructions on previous page to remove belt
cover, drive belt, and drive pulley,
3. With the guard cover off, use the 9/16” socket or
wrench to release tension to the belt by loosening
(do not remove) the two hex bolts holding the
hydraulic pump support bracket. Replace the belt as
needed.
22
3A7600A
Repair
Bearing Housing Replacement
Tools needed:
•
17mm socket or wrench
•
9/16” socket or wrench
•
Adjustable wrench up to 1.5”
•
7/32” hex key
•
Retaining ring pliers
5. With the shaft rotation locked, use the 7/32” hex key
to remove the two set screws on the drive pulley.
Once removed, insert one of the set screws into the
hole directly above the keyway to back out the
bushing. Remove the bushing and pulley.
1. Follow Drum Installation/Replacement, page 12, to
remove the drum.
2. Follow Drive Belt Replacement, page 21, to remove
the drive belt from the machine.
3. Wait until the GrindLazer cools off if it has been
running.
6. With the pulley removed, use retaining ring pliers to
remove retaining ring on shaft. Use the 17mm socket
or wrench to remove the bearing housing assemblies
from the frame and from the Side Plate.
4. With the Side Plate off the machine, use a wrench to
lock the rotation of the shaft. Using the 9/16” socket
or wrench, remove the screw that holds the bushing
to the shaft.
7. Reverse steps to reassemble bearing housing.
NOTE: Replace the rubber spring elements at this
time.
3A7600A
23
Repair
Drive Pulley Replacement
Electric Models
The drive pulleys must be replaced to change between
high speed and standard speed.
Standard Speed: Use the 48-tooth pulley on the motor
shaft and the 56-tooth pulley on the drum shaft with the
1200 mm belt.
Before changing the drive pulleys, follow Drive Belt
Replacement or Hydraulic Belt Replacement (Electric
Models only), page 22, to remove and replace the belt
cover, drive belt, and drive pulleys from the machine.
High Speed: Use the 64-tooth pulley on the motor shaft
and the 34-tooth pulley on the drum shaft with the 1160
mm belt.
For parts diagrams, see Parts - Pulley Assemblies
(Electric - 480V & 380V), page 66.
Flail drums must be used only on standard speed
machines. Using flail drums on high speed machines
will damage the drum and may cause serious injury.
Gas/Propane Models
Standard Speed: Use the 28-tooth pulley on the engine
shaft and the 56-tooth pulley on the drum shaft. Use the
1120 mm belt.
High Speed: Use the 48-tooth pulley on the engine shaft
and the 48-tooth pulley on the drum shaft. Use the 1160
mm belt.
For parts diagrams, see Parts - Pulley Assemblies
(Gas), page 48, and Parts - Pulley Assemblies
(Propane), page 56.
24
3A7600A
Maintenance Checklist
Maintenance Checklist
Gas/Propane: To avoid injury from unexpected start
up, disable engine as follows: 1) Turn DCS Power
Switch OFF. 2) Turn ignition OFF. 3) Disconnect
spark plug wires. 4) Disconnect negative (-) battery
cable from battery.
Electric: To avoid injury from unexpected start up,
disconnect power plug before you service your
machine.
Electric: To avoid injury from unexpected movement,
ensure Power Switch is in the OFF position before
connecting or disconnecting the power cord.
Gas/Propane Models only
•
•
Maintain proper engine oil and crankcase levels.
Change every 25-50 hours (see Kohler manual).
•
Clean spark plugs regularly, and set the proper gap
(see Kohler manual).
All Models
•
Keep a coating of grease on the drive shaft and
threads for easy installation or removal, and for
longer hex bushing life.
•
Every oil change or during routine maintenance,
check all fasteners and re-tighten as needed. The
machine will vibrate the fasteners loose. Use
medium strength thread locking compound.
•
Check the Drive and Hydraulic belts for wear, and
adjust tension (page 22) or replace as needed. After
replacing belts, check for proper tension.
•
Check to ensure the pulleys are aligned properly to
ensure the Drive and Hydraulic belts are running
true.
•
The inside housing must be clean. Remove any
build-up from inside the cage so cutters and drum
rotate freely.
•
Inspect and change drum bushings and shafts every
40 hours, or when worn.
•
Ensure hydraulic fluid level reservoir is filled to the
proper level and inspect fittings for leaks. Tighten as
necessary. For accurate level readings, take
readings when fluid is cold.
Check heavy-duty air cleaner element.
Gas Models
-
Weekly: Check filter minder.
-
*Every 150 Hours: Check heavy-duty air
cleaner element.
-
Every 300 Hours: Replace heavy-duty air
cleaner element and check inner element.
-
Every 600 Hours: Replace heavy-duty inner air
cleaner element.
Propane Models
-
*Every 150 Hours: Check heavy-duty filter
minder. Inspect heavy-duty air filter paper element and inlet screen area.
-
*Every 300 Hours: Replace heavy-duty air
cleaner element and check inner element.
-
*Every 600 Hours or Yearly: Replace
heavy-duty inner air cleaner element.
The hydraulic fluid for the hydraulic drive pump should be
chemically stable and incorporate rust and oxidation
inhibitors.
Specific fluid type meeting these requirements: ISO 68
Synthetic Oil or 15W50 Synthetic Oil.
* Perform these procedures more frequently under
severe, dusty, dirty conditions.
3A7600A
25
Maintenance Checklist
Purge Procedures
Due to the effects air has on efficiency in hydrostatic drive
applications, it is critical that air is removed or purged from
the system.
NOTE: These procedures must be preformed anytime a
hydrostatic system has been opened for maintenance or
repair, or if any additional hydraulic fluid has been added
to the system.
Air creates inefficiency because it has compression and
expansion rates that are higher than that of hydraulic fluid.
Air trapped in the hydraulic fluid may cause the following
symptoms:
1. Noisy operation.
2. Lack of power or drive after short-term operation.
2. With the bypass valve closed and the engine/motor
running, slowly move the directional control in both
forward and reverse directions 5 to 6 times. Check the
oil level, and add hydraulic fluid as required after
stopping engine/motor.
3. It may be necessary to repeat steps 1 and 2 until all
the air is completely purged from the system. When
the drive wheels move forward and reverse at normal
speed, and the reservoir hydraulic fluid remains at a
constant level, purging is complete.
Front Wheel Adjustment
The front wheels can be adjusted independently.
1. Loosen, but do not remove the four nuts holding the
wheel to be adjusted.
3. High operation temperature and excessive
expansion of hydraulic fluid.
Before starting purge procedure, make sure the reservoir
is at the proper oil level. If it is not, fill to top of tank baffle.
The following procedures should be performed with the
drive wheels off the ground, then repeated under normal
operating conditions.
1. With the bypass valve open and the engine/motor
running, slowly move the directional control in both
forward and reverse directions 5 to 6 times. As air is
purged from the unit, the hydraulic fluid level in the
reservoir will drop.
2. Adjust wheel height as needed using height
adjustment bolt.
3. Tighten all nuts to secure wheel into position. Torque
to 23-27 ft-lbs (31.2-36.6 N•m).
26
3A7600A
Recycling and Disposal
Recycling and Disposal
Rechargeable Battery Disposal
End of Product Life
Do not place batteries in the trash. Recycle batteries
according to local regulations. In the USA and Canada,
call 1-800-822-8837 to find recycling location or go to
www.call2recycle.org.
At the end of the product’s useful life, dismantle and
recycle it in a responsible manner.
•
Drain and dispose of fluids according to applicable
regulations. Refer to the material manufacturer’s
Safety Data Sheet.
•
Remove motors, batteries, circuit boards, LCDs
(liquid crystal displays), and other electronic
components. Recycle according to applicable
regulations.
•
Do not dispose of electronic components with
household or commercial waste.
•
3A7600A
Deliver remaining product to a recycling facility.
27
DCS Control Translations
DCS Control Translations
English
Español
Français
Deutsche
FINDING HOME
ENCONTRANDO INICIO TROUVER LE DÉBUT
START FINDEN
HOME
INICIO
DÉBUT
START
DEPTH
ALTURA
HAUTEUR
TIEFE
TARGET
OBJETIVO
OBJECTIF
ZIEL
ZERO
CERO
ZÉRO
NULL
SEL MODEL
MODELO
MODELE
MODELL
LANGUAGE
IDIOMA
LA LANGUE
SPRACHE
UNITS
UNIDAD DE MEDIDA
UNITÉ DE MESURE
MAßEINHEIT
INCHES
MILLIMETERS
PULGADAS
MILIMETROS
POUCES
MILLIMETRES
ZOLL
MILLIMETER
MILS
MILS
MILS
MILS
SOFTWARE REV
SOFTWARE REV
REVUE SOFTWARE
SOFTWARE REV
ERROR
ERROR
ERREUR
FEHLER
28
International
INCH
MM
MIL
3A7600A
DCS Control Translations
English
Español
Français
Deutsche
FREQUENCY
FRECUENCIA
FRÉQUENCE
ANZHAL
HIGH CURRENT
ALTA CORRIENTE
COURANT ÉLEVÉ
HOHER STROM
LOW VOLTAGE
BAJO VOLTAJE
BASSE TENSION
NIEDERSPANNUNG
HIGH VOLTAGE
ALTO VOLTAJE
HAUTE TENSION
HOCHSPANNUNG
HALL SENSORS
SENSORES DE HALL
CAPTEURS DE HALL
HALL-SENSOREN
HOME BUTTON
BOTÓN DE INICIO
BOUTON DE DÉBUT
START KNOPF
ZERO BUTTON
BOTÓN CERO
BOUTON ZÉRO
NULLTASTE
CUT BUTTON
BOTÓN DE CORTAR
BOUTON DE COUPE
SCHNITT TASTE
UP BUTTON
BOTÓN ARRIBA
BOUTON HAUT
NACH OBEN TASTE
DOWN BUTTON
BOTÓN DE ABAJO
BOUTON BAS
NACH UNTEN TASTE
3A7600A
International
29
Troubleshooting
Troubleshooting
Gas/Propane: To avoid injury from unexpected start
up, disable engine as follows: 1) Turn ignition OFF. 2)
Disconnect spark plug wires. 3) Disconnect negative
(-) battery cable from battery.
Electric: To avoid injury from unexpected start up,
disconnect power plug before you service your
machine.
Electric: To avoid injury from unexpected movement,
ensure Power Switch is in the OFF position before
connecting or disconnecting the power cord. In the
event of a power failure or interruption, ensure Power
Switch is in the OFF position before restoring power.
Problem
Cutters wearing unevenly/prematurely
Cutters Shaft Breakage
unevenly/prematurely
Drum wearing prematurely or
cracking
Excess Vibration
Cause
Cutter head is too low
Raise the cutter head
Material build up
Clean the cutters
Bearings may be worn
Replace bearings
Wrong cutters for application
Contact Tech Services
Cutter head is too low
Raise the cutter head
Over 40 hours service life
Replace shafts
Drum hitting work surface
Raise the drum
Shafts and bushings not replaced within 40
hours
Replace shafts and bushings
Bearings may be worn
Replace bearings
Drive shaft worn
Replace drive shaft
Improper cutter set-up
Contact Tech Services
Spindle contacting the work surface
Raise the cutter head
Wheels worn out
Replace the wheels
RPM is too low
Turn engine throttle or speed control to
highest setting
Work surface is severely uneven
Move to smoother work surface
Machine jumps erratically
30
Solution
3A7600A
Troubleshooting
Problem
Cause
Solution
Pulley is misaligned
Re-align pulley
Wrong belt
Order new belt
Hydraulic fluid level may be low
Ensure hydraulic fluid level reservoir is filled
to the proper level
V-belt to hydraulic pump is slipping or damaged
Check V-belt, replace if damaged
Lifting carriage too low / drive wheels not on
work surface
Check lifting carriage is in upright position
and drive wheels are in contact with work
surface
Blown fuse on DCS Power wire.
Replace fuse on DCS Power wire.
Power Switch is OFF or damaged.
Turn Power Switch ON. Replace Power
Switch if danged.
Battery is dead.
Charge Battery.
DCS Control Board is damaged.
Replace DCS Control Board.
DCS Control runs for short time,
then turns off
Engine is not charging the battery. Battery
voltage is 14.0-15.0 VDC when engine is
full throttle and charging correctly.
Check engine charging coil, voltage rectifier/regulator and fuse inside engine ignition
box. Replace or repair if needed.
DCS Control is on, but actuator
and/or drum housing does not
move
Actuator is disconnected from DCS Control.
Check all connections.
A DCS Control Switch is pressed or defective.
Ensure all switches are not stuck. Replace
switches if defective.
Actuator rod is stuck.
Manually move the actuator rod using the
Manual Height Adjustment feature. Remove
screw plug on top of the actuator, then use
6mm hex key to move the rod.
Actuator or DCS Control Board is damaged.
See flow chart, page 33.
Battery is low.
Charge battery.
DCS Control needs to recalibrate its position.
Restart the DCS Control.
Zero Position is not set to the work surface.
Reprogram the Zero Position. See DCS
Instructions, page 19.
The wrong GrindLazer model is selected on
the DCS Control.
Select the correct model on DCS Control.
See Menu Screens, page 15.
The display is unplugged or damaged.
Check that the display ribbon cable and
red/white wire are connected inside Control
Box. Replace if damaged.
Drive belt wearing prematurely
Machine will not move in forward
or reverse
DCS Control not turning on
DCS display does not match Cut
Depth.
DCS Control Buttons work, but
display is blank
3A7600A
31
Troubleshooting
DCS Error Codes
To clear an error code on the DCS Control:
1. Turn DCS Power Switch to OFF.
2. Address/Fix the issue.
3. Turn DCS Power Switch to ON.
Error
Cause
Solution
E04: High Voltage
(20VDC or greater, measured across battery
posts)
Battery is damaged.
Replace battery.
Engine voltage rectifier/regulator is damaged.
Replace engine voltage rectifier/regulator.
E05: High Motor Current
(15 Amps or greater, measured on blue or brown
actuator wire)
Actuator rod is stuck.
Manually move the actuator rod using the
Manual Height Adjustment feature.
Too high of load.
Ensure there is no binding anywhere on the
unit when the actuator is moving.
E08: Low Voltage (7VDC
or lower, measured across
battery posts)
Battery is low/dead.
Charge battery.
Engine is not charging the battery.
Check the engine charging coil and voltage
rectifier/regulator. Replace or repair if
needed.
E09: Hall Sensor Error
Actuator Signal Cable is disconnected from DCS
Control or is damaged.
Check all connections. Repair or replace if
needed.
Actuator or DCS Control Board is damaged.
See flow chart, page 33.
E12: High Current (short
circuit, 60 amps or greater,
measured on red or black
wire between battery and
DCS Control)
A wire or board component has shorted.
Check all wires for shorts. If all wires are
okay, the DCS Control board may be damaged and need to be replaced.
E31: Home Button Error
The Home Button is stuck or shorted.
Check to see if Home Button is stuck. If not
stuck, replace the Home Button switch.
E32: Zero Button Error
The Zero Button is stuck or shorted.
Check to see if Zero Button is stuck. If not
stuck, replace the Zero Button switch.
E33: Cut Depth Button
Error
The Cut Depth Button Error is stuck or shorted.
Check to see if Cut Depth Button is stuck. If
not stuck, replace the Cut Depth Button
switch.
E34: Up Button Error
The Up Button is stuck or shorted.
Clear the error code.
If the error code reappears 30 seconds
after turning the Power Switch back ON,
the problem is the Up Button on the DCS
Control. Check to see if the Up Button is
stuck. If not stuck, replace the Up Button
Switch.
E35: Down Button Error
The Down Button is stuck or shorted.
Clear the error code.
If the error code reappears 30 seconds
after turning the Power Switch back ON,
the problem is the Down Button on the
DCS Control. Check to see if the Down
Button is stuck. If not stuck, replace the
Down Button Switch.
32
3A7600A
Troubleshooting
DCS Actuator Rod Does Not Move
Use this flow chart if the DCS Actuator Rod does not
move or if the DCS displays error code E09 (Hall Sensor
Error). Reference Wiring Diagram, page 68.
Turn power switch to OFF. Remove the blue shroud behind the DCS Control.
Ensure you have a good 12V battery installed. Disconnect the actuator motor
wires and signal cable from the DCS Control. Connect a multimeter between
the blue and brown wires on the DCS Control. Turn the power switch to ON.
Measure the voltage (DC) within 10 seconds of turning the power on. Does it
measure at least 3.0 VDC?
YES
BLUE
BROWN
12V
NO
Connect the blue and brown wires on the
actuator to a good 12VDC battery. First try with
the blue wire on positive post and brown wire
on negative post. If the actuator rod does not
move, put the blue wire on the negative post
and the brown wire on the positive post. Does
the rod move in either case?
YES
NO
REPLACE
ACTUATOR
Within 10 seconds of turning the power switch to ON (while connected to
a good battery), measure the voltage (DC) between the red and black
wires on the actuator signal cable coming from the DCS Control. Does it
measure at least 10 VDC?
YES
NO
REPLACE DCS
CONTROL BOARD
Reconnect the actuator motor wires and signal cable from the actuator to
the DCS Control. Turn the power switch to ON. Does the DCS Control
display the Run Screen within 5 seconds?
YES
REPLACE DCS
CONTROL BOARD
NO
REPLACE
ACTUATOR
ti36057a
3A7600A
33
Parts - Main Housing Assembly (All Models)
Parts - Main Housing Assembly (All Models)
1 Torque to 23-27 ft-lbs
(31.2-36.6N·m)
2 Torque to 40 ft-lbs
(54.2 N·m)
3 Torque to 90-110 in-lbs
(10.2-12.4 N·m)
129
131
132
130
129
ti38091a
34
3A7600A
Parts - Main Housing Assembly (All Models)
Parts List - Main Housing Assembly (All Models)
Ref.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
22
27
33
44
46
47
Part
18B284
18B345
18B370
100021
17W020
100016
18B457
17X017
18B458
18B534
17W425
100020
100023
100133
18B501
18B371
18B347
100022
18B346
100101
100131
101566
17W196
18B288
18B465
18B490
3A7600A
Description
PLATE, side
SKIRT, fixed, left side
PLATE, retaining, left skirt
SCREW, hex, cap, 1/4”-20 x 1”
WASHER, flat, 1/4”
WASHER, lock, 1/4”
NUT, with sleeve, 10mm
BOLT, hex, M10-1.5 x 40mm
O-RING
SPRING, rubber
WASHER, flat, M10
WASHER, lock, M10
WASHER, flat, 3/8”
WASHER, lock, 3/8”
BOLT, hex, head, 3/8”-16 x 1.25”
PLATE, retaining, right skirt
SKIRT, removable, right side
SCREW, hex, cap, 1/4”-20 x .75”
HANDLES, side, plate
SCREW, hex cap, 3/8”-16 x 1”
NUT, hex, 3/8”-16
NUT, nylock, 3/8”-16
SCREW, hex, cap, 3/8-16 x 3”
HOUSING, main
BEARING, flange
WASHER, flat, 3/8”
Qty.
2
1
1
3
11
6
8
8
2
8
8
8
16
16
12
1
1
4
2
4
4
4
2
1
4
16
Ref. Part
48
102637
49
18B352
50
107139
51
17W021
52
102040
53
18B369
54
18B364
55
18B367
56
18B515
57
100071
59
112405
99
18B493
124 19B365
125 19B374
126 19B416
127 19B419
128 19B498
129 16C393
130 16D646
131 19B331
Description
Qty.
SCREW, hex, cap, 3/8”-16 x 1.5” 8
STRIPS, front, brush
1
BOLT, carriage, 1/4”-20x1”
10
WASHER, fender, bend, 1/4 x 1” 5
NUT, nylock, 1/4”-20
14
PLATE, retaining, rear skirt
1
SKIRT, rear
1
PLATE, base, motor
1
SCREW, hex, cap, 3/4”-16 x 5.5” 1
NUT, jam, 3/4”-16
2
NUT, nylock, 3/4”-16
1
WASHER, fender, 3/4”
1
BEARING, side, housing assy.
1
SHAFT, hex
1
BEARING, side, housing, assy.
1
RING, retaining
1
PLUG, inlet
1
LABEL, warning, foot cut
2
LABEL, warning, hot surface
1
LABEL, instructions (Gas and
1
Propane Models)
19B225 LABEL, instructions (Electric
1
Models)
132 19B325 LABEL, warning, entanglement
1
Replacement safety labels, tags, and cards are
available at no cost.
35
Parts - Front Wheel / Wheel Carrier Assemblies (All Models)
Parts - Front Wheel / Wheel Carrier Assemblies (All Models)
2 Torque to 40 ft-lbs
(54.2 N·m)
5 Torque to 34 ft-lbs
(46.1 N·m)
133
ti38092a
135
134
ti38094a
36
3A7600A
Parts - Front Wheel / Wheel Carrier Assemblies (All Models)
Parts List - Front Wheel / Wheel Carrier Assemblies (All Models)
Ref.
5
6
13
14
15
20
23
24
25
26
27
28
29
30
31
32
40
Part
17W020
100016
100023
100133
18B501
100101
18B286
18B385
18B382
404533
101566
18B117
18B381
18B509
17W955
17W098
100333
3A7600A
Description
Qty.
WASHER, flat, 1/4”
1
WASHER, lock, 1/4”
1
WASHER, flat, 3/8”
11
WASHER, lock, 3/8”
3
BOLT, hex, 3/8”-16 x 1.25”
2
SCREW, hex cap, 3/8”-16 x 1”
2
MOUNT, wheel
1
BRACKET, wheel
2
ROLLER, front
2
BOLT, carriage, 3/8”-16 x 1.25”
8
NUT, nylock, 3/8”-16
8
NUT, eye, 3/8-16
2
BUSHING, roller
2
SCREW, hex, cap, 1/2-13 x 5.25” 2
NUT, jam, nylock, 1/2-20
2
WASHER, flat, 1/2”
2
SCREW, hex, cap, 1/4”-20 x .5”
1
Ref. Part
Description
58
169468 WASHER, flat, 3/4”
62
18B380 AXLE, wheel
63
18B466 WHEEL, balance, assy.
79
115625 WASHER, fender, 3/8 x 1.25”
90
18B233 GUARD, rear
133 18B551 LABEL, brand, DC1538 gas
18B552 LABEL, brand, DC1525 propane
18B556 LABEL, brand, DC1520 electric
134 18B550 LABEL, warning, multiple (gas
and propane)
 18B555 LABEL, warning, multiple
(electric)
135 19B215 LABEL, instruction, forward/
reverse
Qty.
2
1
1
2
1
1
1
1
1
1
1
Replacement safety labels, tags, and cards are
available at no cost.
37
Parts - Guidebar / Vacuum Assemblies (All Models)
Parts - Guidebar / Vacuum Assemblies (All Models)
2 Torque to 40 ft-lbs
(54.2 N·m)
3 Torque to 90-110 in-lbs
(10.2-12.4 N·m)
8 Torque to 15 ± 5 ft-lbs
(20.3 ± 6.8 N·m)
ti38093a
ti38096a
38
3A7600A
Parts - Guidebar / Vacuum Assemblies (All Models)
Parts List - Guidebar / Vacuum Hose Assemblies (All Models)
Ref.
4
5
6
13
14
15
21
33
40
45
60
61
80
83
84
85
86
Part
Description
100021 SCREW, hex, cap, 1/4”-20 x 1”
17W020 WASHER, flat, 1/4”
100016 WASHER, lock, 1/4”
100023 WASHER, flat, 3/8”
100133 WASHER, lock, 3/8”
18B501 BOLT, hex, 3/8”-16 x 1.25”
100527 WASHER, flat, 5/16”
17W196 SCREW, hex, cap, 3/8-16 x 3”
100333 SCREW, hex, cap, 1/4”-20 x .5”
18B362 COUPLER, vacuum, 3”
18B361 TEE, vacuum
17W220 PLUG, tube, cap
18B218 GUIDEBAR
19B224 BOARD, control
116610 SCREW, Phillips, 10-32” x .5”
115483 NUT, nylock, 10-32”
17Y111 LINKAGE, upper
3A7600A
Qty.
1
6
6
5
5
3
1
2
6
1
1
2
1
1
4
1
1
Ref. Part
Description
87
18B178 ACTUATOR, 80mm
88
18A114 PIN
89
17Y962 PIN, cotter, bow tie
91
17X233 SCREW, hex, 1/4”-20 x 1.25”
92
18B353 LEVER, transmission
93
18B372 MOUNT, handlebar, saddle
94
18B462 PIN, roll, 1/4”
95
18B455 HANDLE, extension
96
129092 SCREW, hex, 5/16”-24 x 2’
100 19B230 GUARD, wire, rear
121 18B435 FOAM, handlebar
122 18B454 HANDLEBAR
136 15F744 LABEL, warning, ISO pinch
hazard
Qty.
1
1
1
1
1
2
2
1
2
2
2
2
4
Replacement safety labels, tags, and cards are
available at no cost.
39
Parts - Hydraulic Motor / Rear Assembly (All Models)
Parts - Hydraulic Motor / Rear Assembly (All Models)
3 Torque to 90-110 in-lbs
(10.2-12.4 N·m)
7 See manufacturer’s
package
8 Torque to 15 ± 5 ft-lbs
(20.3 ± 6.8 N·m)
ti38097a
68
6
69
72
64
78
77
67
75
73
66
66
58
6
3
18
72
76
7
71
65
70
32
74
71
ti38095a
40
3A7600A
Parts - Hydraulic Motor / Rear Assembly (All Models)
Parts List - Hydraulic Motor / Rear Assembly (All Models)
Ref. Part
5
17W020
6
100016
18
100022
32
17W098
34
18B220
35
130276
36
108788
37
104572
38
19B303
39
18B221
40
100333
41
18B425
42
18B426
43
18B427
58
154526
64
18B398
65
18B469
66
17W088
3A7600A
Description
Qty.
WASHER, flat, 1/4”
2
WASHER, lock, 1/4”
3
SCREW, hex, cap, 1/4”-20 x .75” 1
WASHER, flat, 1/2”
2
MOUNT, motor
1
BOLT, hex, M8 x 1.25 x 30mm
2
WASHER, flat, M8
2
WASHER, lock, M8
2
MOTOR, hydraulic
1
GUARD, Lovejoy
1
SCREW, hex, cap, 1/4”-20 x .5”
2
COUPLING, transmission
1
COUPLING, motor (top)
1
CUSHION, coupling
1
WASHER, flat, 3/4”
2
TRANSMISSION
1
SHAFT, transmission
1
KEY, 1/4” x 2 1/4”
2
Ref. Part
67
18B373
68
18B507
69
16Y269
70
101580
71
18B464
72
17W234
73
108540
74
18B476
75
18B477
76
18B478
77
78
98
18B340
18B519
18B488
18B446
19B303
Description
Qty.
BEARING, drive wheel, flanged
2
SCREW, hex, cap, 1/2”-13 x 2”
4
WASHER, flat, M12
4
NUT, nylock, 1/2”-13
2
COLLAR, split, 1.125”
2
NUT, jam, hex, 3/4”-10
4
NUT, nylock, 3/4”-10
2
CASTER, swivel
2
WHEEL
2
BUSHING, drive, wheel (includes 2
screws)
KEY, 1/4” x 1.875”
2
WASHER, jumbo, 1/4-1.5 x .112” 2
SCREW, flat, 1/4-28 x 3/4
3
HOSE, hydraulic, high pressure
2
(Gas/Propane)
HOSE, hydraulic, high pressure
2
(Electric)
41
Parts - Support System / Hydraulic Tank (All Models)
Parts - Support System / Hydraulic Tank (All Models)
1 Torque to 23-27 ft-lbs
(31.2-36.6N·m)
3 Torque to 90-110 in-lbs
(10.2-12.4 N·m)
136
136
ti38098a
137
138
ti38099a
42
3A7600A
Parts - Support System / Hydraulic Tank (All Models)
Parts List - Support System / Hydraulic Tank (All Models)
Ref. Part
5
17W020
13
100023
14
100133
15
18B501
21
100527
27
101566
28
18B117
52
102040
86
17Y111
89
17Y962
96
129092
101 19B251
102 19B255
103 19B263
104 19B262
106 121233
107 18B996
108 17W080
3A7600A
Description
WASHER, flat, 1/4”
WASHER, flat, 3/8”
WASHER, lock, 3/8”
BOLT, hex, 3/8”-16 x 1.25”
WASHER, flat, 5/16”
NUT, nylock, 3/8”-16
NUT, eye, 3/8-16
NUT, nylock, 1/4”-20
LINKAGE, upper
PIN, cotter, bow tie
SCREW, hex, 5/16”-24 x 2”
BAR, support
SPACER, pin
PIN
PLATE, support
TANK, hydraulic, fluid
BRACKET, hydraulic, tank
BOLT, 3/8”-16 x 1”
Qty.
4
2
1
1
2
1
2
4
1
1
2
2
2
1
2
1
1
4
Ref. Part
109 110838
110 124227
111 100509
112 15H525
113 19B222
114 19B328
115 19B327
116 100132
117 19B329
118 100052
119 114988
120 19B271
136 15F744
137 15K616
138 198921
Description
NUT, nylock, 5/16”-18
SCREW, hex, 5/16”-18 x 1”
PLUG, hydraulic, tank
CAP, screw, hydraulic, tank
FITTING, 90°
SPACER, support, plate
ROLLER, cam
WASHER, 7/16”
NUT, nylock, 7/16”
WASHER, lock, 7/16”
SCREW, hex, 1/4-20 x 1.5
SPRING, support
LABEL, warning, ISO, pinch
LABEL, caution, hot surface
LABEL, instruction
Qty.
2
2
1
1
2
4
4
4
4
4
4
2
4
1
1
Replacement safety labels, tags, and cards are
available at no cost.
43
Parts - Motor / Hydraulic Assemblies (Gas)
Parts - Motor / Hydraulic Assemblies (Gas)
130
1 Torque to 90 ± 5 in-lbs
59
61
(10.2 ± 0.6 N·m)
2 Torque to 30 ± 5 ft-lbs
(40.7 ± 6.8 N·m)
3 Torque to 40 ± 5 ft-lbs
(54.2 ± 6.8 N·m)
8 Torque to 15 ± 5 ft-lbs
(20.3 ± 6.8 N·m)
58
60 4X
3
39 4X
57
25 4X
ti37946a
8
4X
34
32
30
28
14
24
3 2X 25
27
12
132
34
31
29
130
26 25
2X
35
37
1
1 2X 8
10
2X
8
16
38 39
79
32 36
2 6X
ti37947a
44
3A7600A
Parts - Motor / Hydraulic Assemblies (Gas)
Parts List - Motor / Hydraulic Assemblies (Gas)
Ref.
8
10
12
14
16
24
25
26
27
28
29
30
31
32
34
Part
17W020
102040
19B308
19B309
100021
19B304
18B490
102637
101566
19B334
19B333
18B451
19B307
108788
18B517
3A7600A
Description
WASHER, flat, 1/4”
NUT, nylock, 1/4-20
MOUNT, hydro-gear pump
MOUNT, shifter cable
SCREW, hex, cap, 1/4”-20 x 1”
PUMP, hydraulic
WASHER, flat, 3/8”
SCREW, hex, cap, 3/8-16 x 1.5
NUT, nylock, 3/8-16
KEY, 1/8” SQ x 0.5”
COUPLER, Lovejoy, 1/2”
SPIDER
COUPLER, hydrostatic pump
WASHER, flat, M8
SCREW, hex, cap,1.25 x 30mm
Qty.
4
2
1
1
2
1
8
2
2
1
1
1
1
5
4
Ref. Part
Description
Qty.
35
18B368 ARM, pump control
1
36
18B516 SCREW, hex, cap, 1.25 x 16mm
1
37
18B423 BALL, joint
1
38
100023 WASHER, flat, 3/8”
6
39
100133 WASHER, lock, 3/8”
14
57
18B493 WASHER, fender, 3/4”
1
58
18B290 PLATE, motor
1
59
18B356 SHIELD, heat
1
60
18B502 SCREW, hex, cap, 3/8-16 x 1.75” 4
61
18B438 MOTOR, Kohler, 38HP
1
79
18B501 BOLT, hex, 3/8”-16 x 1.25”
1
130 16D646 LABEL, warning, hot surface
1
132 16C394 LABEL, warning, entanglement
1
Replacement safety labels, tags, and cards are
available at no cost.
45
Parts - Hydraulic Fittings / Fuel Tank Assemblies (Gas)
Parts - Hydraulic Fittings / Fuel Tank Assemblies (Gas)
2X
4X
10
8
1
2X
9
1 Torque to 90 ± 5 in-lbs
(10.2 ± 0.6 N·m)
7 Torque to 23 - 27 ft-lbs
4X
6
(31.2 ± 36.6 N·m)
8 Torque to 15 ± 5 ft-lbs
(20.3 ± 6.8 N·m)
4X
2
7 4X
4
3
139
7
5
ti37950a
1
2X
8
2X
8
2
16
77
13
9
23
3 2X
20
130
23
11
2
2X
20
22
77
19
21
23
17
18
ti37948a
46
3A7600A
Parts - Hydraulic Fittings / Fuel Tank Assemblies (Gas)
Parts List - Hydraulic Fittings / Fuel Tank Assemblies (Gas)
Ref.
2
3
4
5
6
7
8
9
10
11
13
16
17
Part
100527
110838
18B366
18B365
19B363
19B340
17W020
100022
102040
124227
18B378
100016
116828
3A7600A
Description
Qty.
WASHER, flat, 5/16”
8
NUT, nylock, 5/16-18
6
BRACKET, gas tank, short
1
BRACKET, gas tank, long
1
BOLT, carriage, 5/16-18 x 1
4
TANK, gas
1
WASHER, flat, 1/4”
6
SCREW, hex, cap, 1/4-20 x 0.75 4
NUT, nylock, 1/4-20
4
SCREW, hex, cap, 5/16-18 x 1
2
MOUNT, hydraulic filter
1
WASHER, lock, 1/4”
2
HEAD, filter, spin-on
1
Ref. Part
Description
18
116830 FILTER, oil
19
18B300 HOSE, hydraulic, 20”
20
18B301 HOSE, hydraulic, 20”
21
18B299 HOSE, hydraulic, 25”
22
18B444 FITTING, adapter, 90°
23
18B443 FITTING, adapter
74
19B332 FITTING, hydraulic, 90°
130 16D646 LABEL, warning, hot surface
139 19Y703 LABEL, warning, multiple
 19Y999 LABEL, warning, multiple icon
Qty.
1
1
1
1
2
4
1
1
1
1
Replacement safety labels, tags, and cards are
available at no cost.
47
Parts - Pulley Assemblies (Gas)
Parts - Pulley Assemblies (Gas)
High Speed
6
64
70
67
1
66
60
65
68
69
132
132
1 Torque to 90 ± 5 in-lbs
(10.2 ± 0.6 N·m)
2 Torque to 30 ± 5 ft-lbs
(40.7 ± 6.8 N·m)
129
60
62
61
63
6
39
40
38
39
40
1
4X
4X
4X
6 See manufacturer’s
package
2
ti37949a
Standard Speed
63
74
73
65
132
132
129
67
ti38083a
48
68
6
66
69
70
1
64
70
71
72
71
2
3A7600A
Parts - Pulley Assemblies (Gas)
Parts List - Pulley Assemblies (Gas)
High Speed (Model 25P474)
Ref.
38
39
40
60
61
62
63
64
65
Part
100023
100133
100101
18B459
18B463
18B363
18B460
18B448
19B396
Description
WASHER, flat, 3/8”
WASHER, lock, 3/8”
SCREW, hex, cap, 3/8-16 x 1”
PULLEY, 48 tooth
BUSHING, tapered, 35mm
KEY, 8mm x 10mm x 1.75”
PULLEY, bottom, stop
BUSHING, tapered, 1-7/16’
GUARD, belt
Qty.
4
5
5
2
1
1
1
1
1
Ref. Part
66
18B492
67
108098
68
18B514
69
19B362
70
18B480
129 16C393
132 16C394
Description
Qty.
WASHER, flat, 5/8”
1
WASHER, lock, M16
1
SCREW, hex, cap, 5/8-18 x 1.5” 1
BELT
1
KEY, 3/8” x 4.25”
1
LABEL, warning, foot cut
1
LABEL, warning, entanglement 2
Qty.
1
1
1
1
1
1
1
5
Ref. Part
Description
71
100133 WASHER, lock, 3/8”
72
100023 WASHER, flat, 3/8”
73
19B499 PULLEY, 28 tooth
74
18B524 SCREW, set
129 16C393 LABEL, warning, foot cut
132 16C394 LABEL, warning, entanglement
Replacement safety labels, tags, and cards are
available at no cost.
Standard Speed (Model 25R100)
Ref.
63
64
65
66
67
68
69
70
Part
Description
18B480 KEY, 3/8” x 4.25”
18B344 BELT
19B396 GUARD, belt
18B363 KEY, 8mm x 10mm x 1.75”
18B590 PULLEY, 56 tooth
19B422 BUSHING, taper, lock, 35mm
18B460 PULLEY, bottom, stop
100101 SCREW, hex, cap, 3/8-16 x 1”
3A7600A
Qty.
5
4
1
1
1
2
Replacement safety labels, tags, and cards are
available at no cost.
49
Parts - Dashboard / Battery Assemblies (Gas)
Parts - Dashboard / Battery Assemblies (Gas)
50
3A7600A
Parts - Dashboard / Battery Assemblies (Gas)
Parts List - Dashboard / Battery Assemblies (Gas)
Ref.
41
42
43
44
45
46
47
48
Part
Description
18B394 CABLE, vernier, control
17W073 SWITCH, kill
17W294 TACHOMETER
17Z193 SWITCH, power, assembly
17Z340 BOOT, toggle
17Y121 BOX, battery
18Y704 FOAM, urethane, 1/2”
18Y701 FOAM, urethane, 1/4”
3A7600A
Qty.
1
1
1
1
1
1
1
3
Ref.
49
50
51
52
53
Part
18Y705
115753
18A786
110823
801958
54
801959
71
18B851
Description
Qty.
FOAM, urethane, 1/4”
1
BATTERY, 35 AH agm
1
STRAP, Velcro, 2” x 24”
1
SCREW, low profile, 1/4-20 x 1” 2
TERMINAL, battery, protector,
1
red
TERMINAL, battery, protector,
1
black
GROMMET, 1 1/16” OD, 3/4” ID 2
51
Parts - Motor / Hydraulic Assemblies (Propane)
Parts - Motor / Hydraulic Assemblies (Propane)
130
1 Torque to 90 ± 5 in-lbs
(10.2 ± 0.6 N·m)
2 Torque to 30 ± 5 ft-lbs
(40.7 ± 6.8 N·m)
3 Torque to 40 ± 5 ft-lbs
(54.2 ± 6.8 N·m)
8 Torque to 15 ± 5 ft-lbs
(20.3 ± 6.8 N·m)
129
132
ti38076a
4X
5
1 2X
9
71
16
6
11
8
12
13
2X 28
10
14
15
7
132
130
14
72
2X
73
4
77
32
2
2
2X 8
25
24
23 4X 8
21
31
19
26
3
20
71
2 2X 17
15
29
1
22
27
23
18
30
52
17 2X
ti38077a
3A7600A
Parts - Motor / Hydraulic Assemblies (Propane)
Parts List - Motor / Hydraulic Assemblies (Propane)
Ref.
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Part
Description
100527 WASHER, flat, 5/16”
110838 NUT, nylock, 5/16-18
124227 SCREW, hex, cap, 5/16-18 x 1
100023 WASHER, flat, 3/8”
100133 WASHER, lock, 3/8”
18B501 BOLT, hex, head, 3/8-16 x 1.25”
18B378 MOUNT, hydraulic filter
17W020 WASHER, flat, 1/4”
100016 WASHER, lock, 1/4”
100022 SCREW, hex, cap, 1/4-20 x .75
116828 HEAD, filter, spin on
116830 FILTER, oil
18B444 FITTING, adapter, 90°
18B443 FITTING, adapter
19B304 PUMP, hydraulic
18B490 WASHER, flat 3/8”
102637 SCREW, hex, cap, 3/8-16 x 1.5
101566 NUT, nylock, 3/8-16
19B334 KEY, 1/8” SQ x 0.5”
19B333 COUPLER, Lovejoy, 1/2”
18B451 SPIDER
108788 WASHER, flat, M8
104572 WASHER, lock, M8
18B517 SCREW, hex, cap,1.25 x 30mm
3A7600A
Qty.
4
2
2
4
8
4
1
4
2
2
1
1
2
3
1
8
2
2
1
1
1
5
4
4
Ref. Part
Description
Qty.
26
18B368 ARM, pump control
1
27
18B516 SCREW, hex, cap, 1.25 x 16mm 1
28
18B445 FITTING, adapter
2
29
18B423 BALL, joint
1
30
19B314 MOUNT, hydro-gear pump
1
31
19B313 COUPLER, hydrostatic pump
1
32
19B315 SHIFTER, hydro gear support
1
57
18B502 SCREW, hex, cap, 3/8-16 x 1.75” 4
58
18B493 WASHER, fender, 3/4”
1
59
18B290 PLATE, motor
1
60
18B439 MOTOR, Kohler, 25HP
1
61
18B431 KIT, muffler
1
62
18B384 BLOCK, mount, heat shield
1
64
18B357 SHIELD, heat
1
66
17W089 SCREW, self tapping, 10-32 x .5” 2
71
18B312 HOSE, hydraulic, 15”
2
72
18B313 HOSE, hydraulic, 16”
1
73
18B742 HOSE, hydraulic, 20”
1
77
19B332 FITTING, hydraulic, 90°
1
129 16C393 LABEL, warning, foot cut
1
130 16D646 LABEL, warning, hot surface
2
132 16C394 LABEL, warning, entanglement
1
Replacement safety labels, tags, and cards are
available at no cost.
53
Parts - Propane Tank / Dashboard Assemblies (Propane)
Parts - Propane Tank / Dashboard Assemblies (Propane)
4X
4
63
140
4X
2
7 Torque to 23 - 27 ft-lbs
(31.2 ± 36.6 N·m)
4X
3
7
ti38079a
67
68
70
69
35
34
36
54
ti38081a
3A7600A
Parts - Propane Tank / Dashboard Assemblies (Propane)
Parts List - Propane Tank / Dashboard Assemblies (Propane)
Ref.
2
3
4
34
35
36
63
67
Part
100527
110838
124227
18B396
17W073
17W294
18B379
18B434
3A7600A
Description
Qty.
WASHER, flat, 5/16”
4
NUT, nylock, 5/16-18
4
SCREW, hex, cap, 5/16-18 x 1 4
CABLE, vernier, control
1
SWITCH, kill
1
TACHOMETER
1
BRACKET, propane, tank
1
LAMP, oil
1
Ref. Part
68
18B120
69
17Z193
70
17Z340
140 19B539
Description
SWITCH, key
SWITCH, power, assembly
TOGGLE, boot
LABEL, warning, fire &
explosion
Qty.
1
1
1
1
Replacement safety labels, tags, and cards are
available at no cost.
55
Parts - Pulley Assemblies (Propane)
Parts - Pulley Assemblies (Propane)
High Speed
6
1
50
46
53
52
55
54
64
51
1 Torque to 90 ± 5 in-lbs
(10.2 ± 0.6 N·m)
132
2 Torque to 30 ± 5 ft-lbs
(40.7 ± 6.8 N·m)
6 See manufacturer’s
package
47
49
18
6
46
48
1
4X
4X 33
5
4X
6
2
6
ti38078a
Standard Speed
59
70
58
60
61
132
1
2
6
68
62
63
64
65
66
67
67
69
ti38082a
56
3A7600A
Parts - Pulley Assemblies (Propane)
Parts List - Pulley Assemblies (Propane)
High-Speed (Model 25P475)
Ref.
5
6
18
33
46
47
48
49
50
Part
Description
Qty.
100023 WASHER, flat, 3/8”
4
100133 WASHER, lock, 3/8”
5
102637 SCREW, hex, cap, 3/8-16 x 1.5” 1
100101 SCREW, hex, cap, 3/8-16 x 1”
4
18B459 PULLEY, 48 tooth
2
18B463 BUSHING, tapered, 35mm
1
19B398 KEY, 8mm x 10mm x 1.75”
1
18B460 PULLEY, bottom, stop
1
18B448 BUSHING, tapered, 1-7/16’
1
Ref. Part
Description
Qty.
51
19B397 GUARD, belt
1
52
19B439 KEY, 3/8” X 3.5”
1
53
18B492 WASHER, flat, 5/8”
1
54
108098 WASHER, lock, M16
1
55
18B514 SCREW, hex, cap, 5/8-18 x 1.5” 1
64
19B362 BELT, power grip
1
132 16C394 LABEL, warning, entanglement 1
Replacement safety labels, tags, and cards are
available at no cost.
Standard-Speed (Model 25R101)
Ref.
58
59
60
61
62
63
64
65
Part
Description
19B499 PULLEY, 28 tooth
19B435 KEY, 3/8” x 3.125”
18B344 BELT, power grip
19B397 GUARD, belt
18B590 PULLEY, 56 tooth
19B422 BUSHING, taper, lock, 35mm
18B363 KEY, 8mm x 10mm x 1.75”
18B460 PULLEY, bottom, stop
3A7600A
Qty.
1
1
1
1
1
1
1
1
Ref. Part
Description
Qty.
66
18B514 SCREW, hex, cap, 3/8-16 x 1.5” 1
67
100133 WASHER, lock, 3/8”
2
68
100101 SCREW, hex, cap, 3/8-16 x 1”
1
69
100023 WASHER, flat, 3/8”
1
70
18B524 SCREW, set
1
132 16C394 LABEL, warning, equipment
1
Replacement safety labels, tags, and cards are
available at no cost.
57
Parts - Battery Assembly (Propane)
Parts - Battery Assembly (Propane)
44
42
45
39
41
39
39
40
38
43
2X
2X 74
37
ti38080a
58
3A7600A
Parts - Battery Assembly (Propane)
Parts List - Battery Assembly (Propane)
Ref. Part
37 17Y121
38 18Y704
39 18Y701
40 18Y705
41 115753
42 18A786
3A7600A
Description
BOX, battery
FOAM, urethane, 1/2”
FOAM, urethane, 1/4”
FOAM, urethane, 1/4”
BATTERY, 35 AH agm
STRAP, Velcro, 2” x 24”
Qty.
1
1
3
1
1
1
Ref. Part
43 110823
44 801958
45
801959
74
18B851
Description
Qty.
SCREW, low profile, 1/4-20 x 1” 2
TERMINAL, battery, protector,
1
red
TERMINAL, battery, protector,
1
black
GROMMET, 1 1/16” OD, 3/4” ID 2
59
Parts - Electrical Components (Electric)
Parts - Electrical Components (Electric)
1 4X 67
66
48
2X 70
55
10
48
52
9
7
2X 50
37 4X
43
4X
132
2X 54
56
6X 6
11
12 13 4X 3
69
7 4X 3
38
27
14
ti38104a
1 Torque to 90 ± 5 in-lbs
(10.2 ± 0.6 N·m)
3 Torque to 40 ± 5 ft-lbs
142
(54.2 ± 6.8 N·m)
7 Torque to 23 - 27 ft-lbs
141
(31.2 ± 36.6 N·m)
8 Torque to 15 ± 5 ft-lbs
(20.3 ± 6.8 N·m)
ti38105a
60
3A7600A
Parts - Electrical Components (Electric)
Parts List - Electrical Components (Electric)
Ref.
2
3
6
7
9
10
11
12
13
14
20
27
37
38
39
40
41
42
43
Part
Description
100133 WASHER, lock, 3/8”
100023 WASHER, flat, 3/8”
117501 SCREW, hex, hd, 8-32 x 1/2”
18B861 CONVERTER, assy, 12V
113956 BOLT, carriage, 3/8”-16 x 1”
19B305 BRACKET, electric starter
18B507 SCREW, hex, 1/2”-13 x 2”
100018 WASHER, lock, 1/2”
17W098 WASHER, flat, 1/2”
18B292 PLATE, motor
100101 SCREW, cap, 3/8”-16 x 1”
101566 NUT, nylock, 3/8”-16
17W020 WASHER, flat, 1/4”
18B579 WASHER, fender, 3/4”
18B753 BOX, junction w/ bolts
100132 WASHER, flat, 7/16”
116645 SCREW, cap, 7/16-20 x 1”
114907 NUT, nylock, 7/16”-20
18B754 MOTOR, electric, 480V, 60Hz
18B755 MOTOR, electric, 380V, 50Hz
3A7600A
Qty.
2
6
6
1
4
1
4
4
4
1
2
4
4
1
1
4
2
2
1
1
Ref. Part
Description
47
18B763 STRAIN, wire, relief, .25-.38
48
18B762 STRAIN, wire, relief, .63-.75
49
102360 WASHER, flat, #10
50
18B851 GROMMET, 1 1/16” OD, 3/4” ID
51
128990 SCREW, head, 10-32 x .75”
52
102040 NUT, nylock, 1/4”-20
54
102920 NUT, nylock, 10-32”
55
109466 NUT, nylock, 8-32”
56
18B846 REDUCER, 1.5” NPT - .75” NPT
66
19B320 BOX, electric, start
67
100021 SCREW, hex, cap, 1/4”-20 x 1”
69
19B485 BRACKET, support
70
116610 SCREW, Phillips, 10-32” x 0.5”
132 16C394 LABEL, warning, entanglement
141 25E178 LABEL, safety, danger (60Hz)
196548 LABEL, caution (50Hz)
142  19B507 LABEL, warning
Qty.
1
5
4
4
4
4
2
4
1
1
4
1
2
1
1
1
1
Replacement safety labels, tags, and cards are
available at no cost.
61
Parts - Hydraulic Motor Assemblies (Electric)
Parts - Hydraulic Motor Assemblies (Electric)
130
129
3 Torque to 40 ± 5 ft-lbs
(54.2 ± 6.8 N·m)
8 Torque to 15 ± 5 ft-lbs
132
(20.3 ± 6.8 N·m)
ti38106a
ti38107a
62
3A7600A
Parts - Hydraulic Motor Assemblies (Electric)
Parts List - Hydraulic Motor Assemblies (Electric)
Ref.
2
3
4
5
8
15
16
18
21
22
23
24
25
Part
100133
100023
18B584
18B501
18B561
18B581
18B582
18B589
18B423
18B445
18B516
18B368
108788
3A7600A
Description
Qty.
WASHER, lock, 3/8”
2
WASHER, flat, 3/8”
2
BELT, hydraulic, pulley
1
BOLT, hex, head, 3/8”-16 x 1.25” 2
GUARD, belt, rear side
1
V-PULLEY (1.625” bore)
1
V-PULLEY (0.625” bore)
1
SUPPORT, gear pump, hydro
1
JOINT, ball
1
FITTING, adapter
2
SCREW, hex, cap, 1.25 x 16mm 1
ARM, pump control
1
WASHER, flat, M8
1
Ref. Part
26
18B339
27
101566
28
102637
29
18B490
30
18B729
32
18B444
44
18B743
45
18B744
129 16C394
130 16D646
132 16C393
Description
Qty.
KEY, 3/16 x .75
1
NUT, nylock, 3/8”-16
2
SCREW, hex, cap, 3/8”-16 x 1.5” 2
WASHER, flat, 3/8”
4
PUMP, hydraulic
1
FITTING, adapter, 90°
2
HOSE, hydraulic, 15”
1
HOSE, hydraulic, 8”
1
LABEL, warning, entanglement
1
LABEL, warning, hot surface
1
LABEL, warning, foot cut
1
Replacement safety labels, tags, and cards are
available at no cost.
63
Parts - Hydraulic Assembly (Electric)
Parts - Hydraulic Assembly (Electric)
1 Torque to 90 ± 5 in-lbs
(10.2 ± 0.6 N·m)
8 Torque to 15 ± 5 ft-lbs
(20.3 ± 6.8 N·m)
ti38108a
64
3A7600A
Parts - Hydraulic Assembly (Electric)
Parts List - Hydraulic Tank Assembly (Electric)
Ref.
17
30
31
32
33
Part
18B585
18B729
18B443
18B444
116830
3A7600A
Description
MOUNT, control, cable
PUMP, hydraulic
FITTING, adapter
FITTING, adapter, 90°
FILTER, oil
Qty.
1
1
1
1
1
Ref.
34
35
36
37
Part
Description
116828
HEAD, filter, spin-on
100022
SCREW, hex, 1/4”-20 x .75”
100016
WASHER, lock, 1/4”
17W020 WASHER, flat, 1/4”
Qty.
1
4
4
4
65
Parts - Pulley Assemblies (Electric - 480V & 380V)
Parts - Pulley Assemblies (Electric - 480V & 380V)
High Speed
132
ti38109a
1 Torque to 90 ± 5 in-lbs
(10.2 ± 0.6 N·m)
2 Torque to 30 ± 5 ft-lbs
(40.7 ± 6.8 N·m)
Standard Speed
6 See manufacturer’s
package
6
56
59
60
57
53
33 48
55
2
65 64 63
1
132
64 62
66
54
1
61
58
47 33
ti38112a
3A7600A
Parts - Pulley Assemblies (Electric - 480V & 380V)
Parts List - Pulley Assemblies (Electric 480V & 380V)
High Speed (Models 25P476 & 25P783)
Ref.
2
3
5
20
37
52
53
57
58
59
Part
Description
100133
WASHER, lock, 3/8”
100023
WASHER, flat, 3/8”
18B501
BOLT, hex, 3/8”-16 x 1.25”
100101
SCREW, hex, 3/8”-16 x 1”
17W020 WASHER, flat, 1/4”
102040
NUT, nylock, 1/4-20
100333
SCREW, hex, 1/4”-20 x .5”
18B587
KEY, step
19B379
PULLEY, 64 tooth
18B558
BUSHING, tapered, 1-5/8”
Qty.
5
4
1
1
2
1
1
1
1
1
Ref. Part
60
19B362
61
19B383
62
18B363
63
19B378
64
18B180
65
18B586
132 16C394
Description
Qty.
BELT, power grip
1
GUARD, belt
1
KEY, 8mm x 10mm
1
PULLEY, 34 tooth, drum side
1
BUSHING, taper, lock, 35mm
1
STOP, pulley
1
LABEL, warning, entanglement 1
Replacement safety labels, tags, and cards are
available at no cost.
Standard Speed (Models 25R102 & 25R103)
Ref.
33
47
48
53
54
55
56
57
58
59
Part
Description
17W020 WASHER, flat, 1/4”
102040
NUT, nylock, 1/4-20
100333
SCREW, hex, 1/4”-20 x .5”
18B587 KEY, step
18B459 PULLEY, 48 tooth
18B463 LOCK, taper, 35mm
19B464 BELT, power grip
19B383 GUARD, belt
18B363 KEY, 8mm x 10mm
18B590 PULLEY, 56 tooth
3A7600A
Qty.
2
1
1
1
1
1
1
1
1
1
Ref. Part
Description
Qty.
60
18B588 BUSHING, tapered, 1-5/8”
1
61
18B586 STOP, pulley
1
62
18B501 BOLT, head, 3/8-16 x 1.25”
1
63
100101
SCREW, hex, cap, 3/8-16 x 1”
1
64
100133
WASHER, lock, 3/8”
2
65
100023
WASHER, flat, 3/8”
1
132 16C394 LABEL, warning, entanglement 1
Replacement safety labels, tags, and cards are
available at no cost.
67
Wiring Diagram
Wiring Diagram
Gas Models
68
3A7600A
Wiring Diagram
Propane Models
3A7600A
69
Wiring Diagram
Electric Models (480V)
70
3A7600A
Wiring Diagram
Electric Models (380V)
3A7600A
71
Technical Data
Technical Data
DC1538 G DCS (Models 25P474 / 25R100)
Maximum Working Pressure
Noise level (dBa)
Sound power
1750 psi
121 bar, 12.1 MPa
107 dBa per ISO 3744
Sound pressure
Vibration level*
91 dBa measured at 3.1 feet (1m)
Right/Left Hand
14.5 m/sec2
* Vibration measured per ISO 5349 based on 8 hour daily exposure
Dimensions/Weight (unpackaged)
US
Height
42 in.
Length
57 in.
Width
46 in.
Weight
725 lb
Metric
107 cm
145 cm
117 cm
329 kg
DC1525 P DCS (Models 25P475 / 25R101)
Maximum Working Pressure
Noise level (dBa)
Sound power
1750 psi
121 bar, 12.1 MPa
106 dBa per ISO 3744
Sound pressure
Vibration level*
90 dBa measured at 3.1 feet (1m)
Right/Left Hand
10.0 m/sec2
* Vibration measured per ISO 5349 based on 8 hour daily exposure
Dimensions/Weight (unpackaged)
US
Height
42 in.
Length
60 in.
Width
46 in.
Weight
715 lb
Metric
107 cm
152 cm
117 cm
324 kg
DC1520 E DCS (Models 25P476 / 25R102 / 25P783 / 25R103)
Maximum Working Pressure
Power Requirements
25P476 / 25R102
25P783 / 25R103
Noise level (dBa)
Sound power
1750 psi
121 bar, 12.1 MPa
480V, 60 Hz, 3 phase, 25 A
380V, 50 Hz, 3 phase, 28 A
105 dBa per ISO 3744
Sound pressure
Vibration level*
88 dBa measured at 3.1 feet (1m)
Right/Left Hand
6.9 m/sec2
* Vibration measured per ISO 5349 based on 8 hour daily exposure
Dimensions/Weight (unpackaged)
US
Height
36 in.
Length
60 in.
Width
46 in.
Weight
910 lb
72
Metric
91 cm
152 cm
117 cm
413 kg
3A7600A
Technical Data
California Proposition 65
CALIFORNIA RESIDENTS
WARNING: Cancer and reproductive harm – www.P65warnings.ca.gov.
3A7600A
73
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects
in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited
warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment
determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance
with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or
substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for
verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in
material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and
transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the
date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are
subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for
breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach
of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent
avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires
exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
For patent information, see www.graco.com/patents.
TO PLACE AN ORDER, contact your Graco distributor or call 1-800-690-2894 to identify the nearest distributor.
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 3A7600
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2020, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision A, June 2020

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