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AIRLESSCO 25M232, Operation - Repair - Parts, Page: 37 / 72

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AIRLESSCO 25M232 Operation - Repair - Parts Download Page 37

Battery

3A4637A Operation, Repair, Parts

37

Battery

Removal 

1. Shut off engine, turn off the self-propelled drive 

system, switch to neutral and engage the parking 

brake.

2. Remove battery cover (323).

3. Unscrew M5 terminal screws (358) to disconnect 

battery from wire harness.

4. Remove battery (321) from bracket (320).

I

O

Neutral

ti30421a

ti30423a

ti30424a

ti30425a

Summary of Contents for 25M232

Page 1: ...5M232 3300 psi 22 8 MPa 228 bar Maximum Operating Pressure Important Safety Instructions Read all warnings and instructions in this manual related manuals and on the equipment Be familiar with the con...

Page 2: ...4 Removal 34 Installation 34 Pressure Control On Off Switch 35 Removal 35 Installation 35 Pressure Adjust Potentiometer 36 Removal 36 Installation 36 Control Board 36 Removal 36 Installation 36 Batter...

Page 3: ...parts Check hoses and parts for signs of damage Replace any damaged hoses or parts This system is capable of producing 3300 psi Use Graco replacement parts or accessories that are rated a minimum of 3...

Page 4: ...ces Do not kink or over bend hoses or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations MOVING PARTS HAZARD Moving parts can pinch...

Page 5: ...not limited to Protective eyewear and hearing protection Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer CALIFORNIA PROPOSITION 65 The engine exhaust fr...

Page 6: ...15 69321ST 6 15 69323ST 6 8 15 20 69325ST 6 8 15 20 69417ST 6 8 15 20 69419ST 8 10 20 25 69421ST 8 10 20 25 69423ST 8 10 20 25 69425ST 8 10 20 25 69427ST 8 10 20 25 69431ST 8 10 20 25 69621ST 12 14 30...

Page 7: ...3 4 5 6 7 8 9 10 12 13 14 16 18 20 I O ti30694a 1 Engine Controls 2 Filter 3 Gauge 4 Prime Spray 5 Drain Hose 6 Suction Tube 7 Speed Control 8 Drive Power Switch 9 Pump Switch 10 Pressure Control 11 S...

Page 8: ...ngage the trigger lock Turn prime valve down 5 If you suspect the spray tip or hose is clogged or that pressure has not been fully relieved a VERY SLOWLY loosen tip guard retaining nut or hose end cou...

Page 9: ...URS OR ANNUALLY Clean air filter Clean pre cleaner EVERY 50 HOURS OR ANNUALLY Change engine oil Service exhaust system EVERY 100 HOURS Change gear reduction oil if equipped ANNUALLY Replace spark plug...

Page 10: ...Stratton engine manual 4 Fill fuel tank See Briggs Stratton engine manual 5 Check that tires are inflated to recommended pressure The equipment must be grounded to reduce the risk of static sparking S...

Page 11: ...switch to power the drive system 3 Move the Engine Kill Drive Power switch to the middle position to shut off the drive system Fully depress the top portion of the Engine Kill Drive Power switch to sh...

Page 12: ...in no motion and turning the speed knob fully clockwise will result in maximum speed Changes in the terrain may require adjusting the speed i e moving from turf to pavement Speed Control 1 With the e...

Page 13: ...g fluid Attach ground wire to pail and to true earth ground Use water to flush water base paint and mineral spirits to flush oil base paint and storage oil 3 Turn prime valve down 4 Turn pressure cont...

Page 14: ...valve to open b Move choke to closed c Set throttle to fast d Pull starter cord e After engine starts move choke to open f Set throttle to slow ti29206b ti29207b ti29208b NOTICE Do not run pump witho...

Page 15: ...smoothly 12 Inspect fittings for leaks Do not stop leaks with your hand or a rag If leaks occur turn striper OFF imme diately Perform Grounding Procedure For Flam mable Materials Only page 8 Tighten...

Page 16: ...are installed properly 1 Perform Pressure Relief Procedure page 8 2 Engage trigger lock Insert seat and Uni Tip Seal Insert Uni Tip 3 Screw assembly onto gun Hand tighten To avoid serious injury from...

Page 17: ...o gun holder with hose guard pressed against the holder assembly bracket Tighten gun into clamp Position Gun 2 Position gun up down and forward reverse 3 Position gun left right a Right side gun posit...

Page 18: ...nd side 4 For Curb Position place gun at 45 angle 5 For Gun Arc Spray Position place gun at rear of striper Rear position improves arc quality NOTE Verify that the gun can still be triggered and that...

Page 19: ...pressure to eliminate heavy edges Use smaller tip size if pressure adjustment can not eliminate heavy edges Clearing Tip Clogs 1 Release trigger Engage gun trigger lock Rotate Uni Tip Disengage gun t...

Page 20: ...filter 4 Clean gun filter Uni Tip Guard and Uni Tip in flushing fluid See Flushing Recommendations page 23 5 Remove siphon tube set from paint and place in flushing fluid Use water or pump conditioner...

Page 21: ...system Release trigger and engage trigger lock 11 Open prime valve and allow flushing fluid to circu late for 20 seconds to clean drain tube 12 Raise siphon tube above flushing fluid and run striper f...

Page 22: ...d gasket with a soft bristle brush to prevent part failure due to dried materials Assemble parts and attach loosely onto gun 17 Wipe striper hose and gun with a rag soaked in water or mineral spirits...

Page 23: ...al spirits Spray water base paint Warm soapy water then clean water Water base paint Warm soapy water then clean water Mineral spirits Spray oil base paint Mineral spirits Oil base paint Mineral spiri...

Page 24: ...uid filter is dirty Clean filter Tip or tip filter is clogged Clean tip or tip filter see gun manual Displacement pump piston rod is stuck due to dried paint Repair pump see pump manual Connecting rod...

Page 25: ...ighten throat packing nut just enough to stop leakage Throat packings are worn or damaged Replace packings See pump manual Displacement rod is worn or damaged Replace rod See pump manual Fluid is spit...

Page 26: ...sure Relief Procedure page 8 3 Loosen two screws 32 and remove pump rod cover 107 4 Remove hose 118 and suction hose 57 Use screwdriver push retaining spring 28 up push out pin 31 5 Loosen jam nut by...

Page 27: ...side Tighten jam nut by hand then tap 1 8 to 1 4 turn with a 20 oz maximum hammer to approximately 75 5 ft lb 102 N m Connect hose 118 and suction hose 57 4 Fill packing nut with TSO until fluid flow...

Page 28: ...grease to washers 46 49 and 48 Install in order shown 4 Lubricate gears with 0 26 pint of 110293 grease supplied with drive housing Pack grease evenly around gears 5 Clean mating surfaces of pinion a...

Page 29: ...g Rod page 28 2 Disconnect clutch and clutch connectors from wire harness located under sprayer cart 3 Remove four screws 34 and pinion assembly 44 4 Place pinion assembly 44 on bench with rotor side...

Page 30: ...ine drive shaft 5 Install four screws 36 and lock washers 35 with torque of 125 in lb Pinion Assembly 1 Check o ring 44e and replace if missing or damaged 2 Tap pinion shaft 44c in with plastic mallet...

Page 31: ...clamp Clamp Installation 1 Install engine shaft key 37 2 Tap clamp 38 onto engine shaft A Maintain dimension shown note 2 Chamfer must face engine 3 Check dimension Place rigid straight steel bar B ac...

Page 32: ...t hold clutch housing 45 to engine 3 Remove screw 145 from under mounting plate 4 Pull off clutch housing 45 Installation 1 Push on clutch housing 45 2 Install four cap screws 51 and lock washers 50 a...

Page 33: ...page 32 Installation 1 Lift engine carefully and place on cart 2 Install two screws 110 in base of engine and secure with lock nuts 111 Torque to 20 ft lb 27 12 N m 3 Connect all necessary wiring 4 I...

Page 34: ...ard 62e 3 Pull transducer connector through strain relief bushing 151 4 Remove transducer and o ring 99 from filter housing 67 Installation 1 Install o ring 99 and transducer 155 in filter hous ing 67...

Page 35: ...h side of ON OFF switch 62d and remove switch from cover Installation 1 Install new ON OFF switch 62d so tabs of switch snap into place on inside of cover 2 Connect ON OFF switch connector B to pressu...

Page 36: ...pin on cover 62a b After adjustment of step a tighten both set screws in knob 1 4 to 3 8 turn after contact with shaft 3 Connect potentiometer 62b cable to control board 62e 4 Close cover 62a and secu...

Page 37: ...turn off the self propelled drive system switch to neutral and engage the parking brake 2 Remove battery cover 323 3 Unscrew M5 terminal screws 358 to disconnect battery from wire harness 4 Remove ba...

Page 38: ...23 and secure with strap 322 Drive Motor Removal 1 Shut off engine turn off self propelled drive system switch to neutral and engage the parking brake 2 Disconnect battery 321 or remove fuse near batt...

Page 39: ...ol board and the blue motor wire from the blue wire that runs up to the handlebar switch 330 5 Loosen the two bolts 314 that secure the motor mount to the frame and slide the motor completely forward...

Page 40: ...placed into the chain 316 slide thesprocket ontothe motor shaft while placing the motor 311 into the motor bracket 310 and secure the motor to the motor bracket with four M6 screws 312 Torque to 50 60...

Page 41: ...wires secure wires with strain relief bushing and close the control box cover 6 Reconnect the battery 321 or replace the fuse Turn ON the self propelled drive With the brake ON and the right wheel sec...

Page 42: ...holding the wheel 3 to keep the axle from spinning loosen and remove the axle nut 307 Slide the wheel off the axle 300 making sure to retain the key 306 Installation 1 With the key placed into the key...

Page 43: ...control box 4 Remove the strain relief bushing 333 and disconnect the blue wire from A on the control board and from the blue motor wire Disconnect the white wire from HI on the control board 62e and...

Page 44: ...white wires to the control board 324 motor and speed control 4 Replace the strain relief bushing 333 and close control box cover 62a 5 With the self propelled drive system switch in the OFF position a...

Page 45: ...r and securely elevate the rear of the striper a 3 While holding the wheel 3 to keep the axle 300 from spinning loosen and remove the axle nut 307 Slide the wheel off the axle making sure to retain th...

Page 46: ...ide each bracket bearing assembly off of the axle 300 8 If replacing the axle bearings unbolt each bearing 304 and 305 from the axle bracket 302 Installation 1 If replacing the axle bearings bolt each...

Page 47: ...hten all set screws 6 Wrap the chain 316 around the axle and motor sprockets and reconnect using the master link Slight repositioning of the motor may be required 7 With the key 306 inserted into the...

Page 48: ...nnect the master link on the chain and remove the chain 316 Installation 1 Wrap the chain around the axle and motor sprocket and reconnect using the master link 2 If the chain cannot be connected or t...

Page 49: ...brake 2 Remove the 30 amp fuse from the fuse holder near the battery 3 Open the control box cover 62a and carefully disconnect the seven wires that are connected to the male spade terminals and the o...

Page 50: ...labels 3 Close the control box cover 62a ensure the drive power switch 62m is in the OFF position and reinsert the 30 amp fuse ti30514a REGULATOR RECTIFIER ENGINE FUSE BATTERY DRIVE ON OFF ENGINE KIL...

Page 51: ...propelled drive system switch to neutral and engage parking brake 2 Open control box cover 62a and carefully discon nect three wires 3 Remove the speed knob 62h using a 5 64 allen wrench the friction...

Page 52: ...iction o ring 62k onto the stud 2 Turn the potentiometer stud completely counter clockwise then place the speed knob 62n onto the stud With the indicator aligned with the first tick mark and while pre...

Page 53: ...and or ensure it is connected with the red wire to positive and the black wire to negative Install or replace with 30A automotive fuse Run engine at full RPM to charge battery to at least 13v Chargin...

Page 54: ...See the proper fluid pump manual for the sprayer for further troubleshooting procedures YES Disconnect clutch wires from control board see diagram pages 17 48 Does the pump stop running Mechanical pro...

Page 55: ...tch Go to step 3 Is 10 12 VDC present YES Go to step 4 Is 1 3 Ohms reading present YES Mechanical problem Repair or place clutch pinion assembly NO If low resistance is present in step 4 the problem i...

Page 56: ...r to high and set meter to DC volts J1 CONTROL BOARD J2 Engine Generator 12 20AC V ti29063b STEP 4 Turn engine OFF and unplug clutch wires Set meter to Ohms STEP 5 Turn engine ON and turn switch ON BE...

Page 57: ...50 ft minimum Smaller hose or metal braid hose may result in pressure spikes 4 Replace transducer if fluid path is not clogged and proper hose is used Red LED 3 blinks continuous Sprayer stops Engine...

Page 58: ...18 96 97 132 9 85 143 328 55 66 89 323 322 319 19 130 54 15 110 9 93 64 74 5 5 6 65 2 26 111 4 64 93 84 14 92 172 10 11 153 115 7 91 112 114 8 319 300 302 306 314 317 72 87 13 86 150 3 307 131 358 357...

Page 59: ...1 93 119554 NUT lock nylon thin pattern 2 96 129382 STRAP hose wrap 1 97 116935 SCREW cap flng hd 2 110 110837 SCREW flange hex 2 111 110838 NUT lock 2 112 122669 WASHER flat extra thick 1 114 110963...

Page 60: ...Parts Drawing 60 3A4637A Operation Repair Parts Parts Drawing Self Propelled Drive 300 301 312 313 314 317 319 339 309 305 310 315 311 319 317 319 304 303 308 316 305 302 305 ti30602a...

Page 61: ...lange 10 308 111802 SCREW cap hex hd 4 309 112731 NUT hex flanged 4 310 17P354 BRACKET motor 1 311 17N311 MOTOR 12V DC gear 1 312 121518 SCREW cap shc 4 313 129467 SPROCKET 12 tooth 1 314 120229 SCREW...

Page 62: ...3A4637A Operation Repair Parts Parts Drawing 45 20 146 145 40 51 50 39 38 44ref 41 42 36 35 35 35 35 36 34 46 49 48 47 34 34 52 107 32 142 32 43 141 118 30 27 31 29 28 33 130ref 57 136 56 140 139 75 6...

Page 63: ...cludes 32 34 1 45 17M314 HOUSING clutch machine 1 46 116074 WASHER thrust 1 47 287484 CRANK includes 46 48 49 1 48 180131 BEARING thrust 1 49 107434 BEARING thrust 1 50 100214 WASHER lock 4 51 108842...

Page 64: ...ist Pinion Housing Ref No 44 Pinion Housing May be ordered separately Ref Part Description Qty 44 17R785 HOUSING pinion kit 1 44a 17R793 KIT repair coil 1 44b 105489 PIN 2 44c 17R788 PINION SHAFT 1 44...

Page 65: ...d 24Y991 KIT pivot 1 20e 15F211 STUD cable 1 20f 102040 NUT lock 3 20g 24Y991 KIT pivot 1 21 248200 GUARD Uni Tip 1 23 287566 KIT clamp 1 24 17J145 ARM holder gun 1 25 15F213 BRACKET cable 1 59 15E992...

Page 66: ...134a 67 ref 13 87 99 155 18ref 75ref 118ref 106 141ref 101 102 152 152 195 182 205 196 106 98 100 105 103 104 63 32 62n 62m 62k 62e 62h 62d 62c 62b 62j 62b 62p 342 62f 62e 62g 62a 62 129 350 B 350 348...

Page 67: ...1 102 239914 VALVE drain 1 103 117285 O RING 1 104 243984 FILTER fluid 1 105 15C766 TUBE diffusion 1 106 196177 ADAPTER nipple 2 129 101550 SCREW cap sch 2 148 237686 WIRE ground assembly w clamp 1 15...

Page 68: ...TOR RECTIFIER 15a ENGINE BATTERY DRIVE ON OFF ENGINE KILL SPEED CONTROL J2 J1 CRUISE NEUTRAL DRIVE SWITCH L W H A A B B MOTOR CONTROL BOARD FUSE BLACK BLACK BLACK WHITE WHITE BLUE PINK YELLOW YELLOW Y...

Page 69: ...Diagram REGULATOR RECTIFIER 15a ENGINE FUSE BATTERY DRIVE ON OFF ENGINE KILL SPEED CONTROL DRIVE MOTOR CRUISE NEUTRAL DRIVE SWITCH L W H A A B B MOTOR CONTROL BOARD ti30700a BLACK BLACK BLUE YELLOW BL...

Page 70: ...luid outlet size 0 25 in diameter Vibration per ISO 5349 Right Hand 163 in s2 4 14 m s2 Left Hand 234 in s2 5 94 m s2 Sound power per ISO 3741 95 5 dBa Wetted parts stainless steel PTFE leather nylon...

Page 71: ...Notes 3A4637A Operation Repair Parts 71 Notes...

Page 72: ...o 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...

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