Graco 332230R Owner's Manual

Installation - Operation - Parts
Complete Pressurized Bead System for
LineLazer 200HS/DC/MMA and LineLazer
250SPS/DC/MMA
332230R
EN
- For professional use only -
Models:
25R268 1-Gun LL200HS/MMA
25R270 1-Gun LL250SPS/MMA
25R267 2-Gun LL200HS/DC/MMA
25R269 2-Gun LL250SPS/DC/MMA
80 psi (.55 MPa, 5.5 bar) Maximum Working Pressure
9
Important Safety Instructions
Read all warnings and instructions in the striper manual. Be familiar
with the controls and the proper usage of the equipment. Save these
instructions.
Related Manual
Bead Gun Kit
332226
LLIV 200HS Repair
311021
LLV 200HS/DC Repair and Parts 3A3390
LLV 200MMA Operation, Repair, 3A6466
and Parts
250DC Repair
334053
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
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and
explosion:
• Use equipment only in well ventilated area.
• 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.
• Keep work area free of debris, including solvent, rags and gasoline.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are antistatic
or conductive.
• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
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 exceed the maximum working pressure or temperature rating of the lowest rated system component.
See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment
manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material,
request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure 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. Alterations or modifications may void agency approvals and create safety
hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• 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.
• Do not carry passengers.
• Check work area for reduced overhead clearance (e.g. doorways, tree branches, parking ramp ceilings) and
avoid contacting them.
2
332230R
Warnings
WARNING
INJECTION HAZARD
High-pressure fluid from gun, 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.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing
equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
ENTANGLEMENT HAZARD
Rotating parts can cause serious injury.
• 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.
• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the
Pressure Relief Procedure and disconnect all power sources.
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.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the
Pressure Relief Procedure and disconnect all power sources.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:
• Do not touch hot fluid or equipment.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury,
hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:
• Protective eye wear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
CALIFORNIA PROPOSITION 65
The engine exhaust from this product contains a chemical known to the State of California to cause cancer, birth
defects or other reproductive harm.
This product contains a chemical known to the State of California to cause cancer, birth defects or other reproductive harm. Wash hands after handling.
NOTICE
Never store glass beads in tank between jobs. Begin the day with moisture-free beads. Moisture will cause glass beads to resist flow or
solidify over time.
If moisture or condensation is present on tank interior, leave lid open until dry. When operating without the bead system, always leave
the moisture drain valve open.
332230R
3
Tools Needed:
CE Safety Checklist
(To be completed during non-factory installation)
Covers and shrouds for moving parts are in place (see guard installation section).
Fasteners, belts, covers, grills, and compressor are tight-mounted securely.
Read and understand all warnings and instructions in this manual and the striper manual.
Tools Needed:
•
1/8 in. Allen Wrench (supplied with kit)
•
Alignment tool 17C504 (supplied with kit)
•
5/32 in. Allen Wrench
•
1/4 in. Allen Wrench
•
3/16 in. Allen Wrench
•
7/16 in. Wrench
•
3/8 in. Wrench
•
1/2 in. Wrench
•
5/8 in. Wrench
•
9/16 in. Wrench
•
11/16 in. Wrench
•
T-20 Torx Bit
•
Cutting Blade
•
Rubber Mallet
•
Phillips Screwdriver
•
Straight Edge
•
2.5 mm Allen wrench
•
4 mm Allen wrench
4
332230R
Operation for LL200 and LL250
Operation for LL200 and LL250
Component Identification
Ref. Description
1
2
3
4
Funnel
Wing Nut
Compressor Bypass Switch
Regulator Unloader
332230R
Ref. Description
5
6
7
8
9
Pressure Relief Valve
Bead Tank Gauge
Pressure Regulator Valve
Air Tank Gauge
Safety Relief Valve
5
Pressure Relief Procedure
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
3. Loosen wing nut (2) until it reaches end of threads.
If any remaining pressure is in bead tank, it will be
released through seal while wing nut secures lid to
hopper. Confirm pressure is at 0 psi (0 bar, 0 MPa)
and open lid.
2
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing fluid
and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning,
checking, or servicing the equipment.
ti21077a
1. Turn engine OFF.
2. Release pressure on bead tank to 0 psi (0 bar, 0
MPa). Turn pressure relief valve (8) to vertical position and watch bead tank pressure gauge until pressure reads 0 psi (0 bar, 0 MPa). Do not use safety
valve (3) to release pressure from bead tank.
3
8
ti21075a
6
4. Secure lid over opening and tighten wing nut until lid
is level with hopper.
ti21080a
ti21081a
332230R
200HC/DC/MMA Pressurized Bead System Kit 25R268
200HC/DC/MMA Pressurized Bead System Kit 25R268
Assemble Compressor Mounting
and Drive Components
3. Assemble hopper basket (XX) and base with hardware as shown below. Use 9/16 in. wrench to snug
screws. Loosen all six screws 1/4 turn.
NOTE: Glass bead system and paint guns can be
mounted on either side of sprayer.
1. Turn off unit. Perform Pressure Relief Procedure
page 6.
2. Loosely install two screws (MM) and two locknuts
(NN) through bottom of frame mount but do not
tighten. Remove existing gun arm bracket to gain
access to nut (NN).
XX
ti21194a
MM
NN
ti21201a
332230R
7
200HC/DC/MMA Pressurized Bead System Kit 25R268
Complete Frame Assembly
2. Install plastic end caps (ZZ) into frame. Use rubber
mallet to pound end caps into place.
NOTE: If desired, rotate recoil 90° counter-clockwise.
ZZ
ti21500a
1. Use 9/16 wrench to tighten bottom screws (MM) to
hardware shown.
ti20884a
MM
ti21200a
8
332230R
LL200 Compressor Installation
LL200 Compressor Installation
Tools Needed: 2.5 mm Allen wrench, 4.0 mm Allen wrench,
1/4 in. Allen wrench, 7/16 in. wrench, 9/16 in. wrench, 11/16 in.
wrench, T-20 Torx bit, rubber mallet, Phillips screwdriver.
5. With a 9/16 in. wrench, mount air tank (53) to
bracket with screws (21).
Replacing the compressor requires pulling on the
starting rope. To help prevent entanglement, pinching,
and potentially serious injury from an unexpected
start-up, disconnect the spark plug prior to compressor
replacement.
1. Turn engine OFF. Let engine cool prior to working
on it.
2. Disconnect spark plug on unit.
3. Perform Pressure Relief Procedure page 6.
4. Using bolts (36) and lock nuts (22), install air tank
bracket (3).
6. Use the T-20 star bit to remove fan grill from shroud.
Save screws for reattachment.
332230R
9
LL200 Compressor Installation
7. Locate belt shroud. Loosen knob and rotate shroud.
12. Torque pulley set screws to 58-62 in-lb (6.6-7 N•m).
13. Install belt on pulley. Refer to Ground Drive Belt
Replacement in your striper repair manual for
additional instructions and belt tension
recommendations.
NOTE: Before performing step 14, securing nuts to back
of pulley with piece of duct tape will assist with
installation.
8. Using a 1/4 in. Allen wrench, remove shoulder bolts
and serrated nuts securing existing coupler plate.
14. Put belt shroud down, install shaft coupler (5) onto
pulley with two shoulder screws (18) and serrated
nuts (19). Position slot on back of pulley up and
move serrated nut with finger to accept shoulder
bolt threads. Tighten using shoulder bolt by hand
until the teeth on the serrated nut catch the
aluminum on the fan. Using a 1/4 in. Allen wrench,
torque to 16-18 ft-lb (21-24 N•m).
NOTE: Do not use ball end Allen wrenches, as they
may break and become stuck in the screws.
9. Loosen set screws on pulley. Lift engine to provide
slack for the belt and remove old pulley (X).
10. File any rough spots on the pump shaft key.
11. Slide new pulley on to the pump shaft. Pump shaft
must extend 0.125-0.225 in. (3.175-5.73 mm)
beyond the face of the pulley. The pump shaft is the
pilot for the coupler adapter.
10
332230R
LL200 Compressor Installation
15. Use existing screws to install new fan grill with
opening (FF) onto belt. Do not over-tighten screws.
Make sure fan grill protrudes out; not into the
shroud.
16. Position compressor bracket (4) with three tabs
facing towards the fan grill. Center shaft coupler
both vertically and horizontally in slot. Insert four
screws (20) through the slots in the compressor
bracket and tighten to 23-27 ft-lb (31-37 N•m).
17. Place drop of medium strength thread locker on the
threads of each set screw. Using a 2.5 mm and a
4.0 mm Allen wrench, screw the set screws into the
shaft collar far enough so that the shaft collar can
slide on the compressor shaft. Rotate the shaft
collar so the pin faces up. Align the shaft collar pin
with the compressor shaft keyway as shown. Slide
the shaft collar onto the compressor shaft, pin first.
332230R
11
LL200 Compressor Installation
18. Slowly pull the starter rope to rotate shaft so that the
shaft keyway (5) faces up. Place the key (2) into the
shaft keyway. A light tap with a rubber mallet may
be needed to ensure the key seats completely.
19. Slide compressor onto the shaft coupler mounting
plate until the face of the compressor is flush with
compressor bracket. Rotate the compressor 90
degrees counter-clockwise until the set screw is
accessible.
NOTICE
Performing steps 19 through 23 out of order, or
incorrectly, may cause excessive side loading on the
compressor crankshaft and could cause a premature
failure of the compressor.
12
332230R
LL200 Compressor Installation
20. Use two carriage bolts, two washers, and two nuts
in opposing holes (180 degrees apart) to tighten the
compressor to the compressor bracket.
21. Slowly pull the starter rope to rotate until the two
M8x10 set screws appear in the set screw access.
Torque the set screws to 150-160 in-lb (16.9-18
N•m). Again, slowly pull the starter rope until the
single M5x8 set screw appears in the access and
tighten it to 37-42 in-lb (4-4.7 N•m).
NOTE: Do not use ball end Allen wrenches, as they
may break and become stuck in the screws.
22. Remove two carriage bolts, two washers, and two
nuts in opposing holes (180 degrees apart), and
rotate the compressor clockwise 90 degrees back to
the upright orientation.
332230R
13
LL200 Compressor Installation
23. With the compressor secured to the coupler
mounting plate, slightly loosen the four mounting
screws (20). Install all four carriage bolts (9),
washers (10), and lock nuts (11), and torque to
150-160 in-lb (16.9-18 N•m). Re-tighten all four
mounting screws (20) to 23-27 ft-lb (31-37 N•m).
24. Install compressor guard using three screws (14),
lock washers (15), and flat washers (16). Torque to
130-150 in-lb (14.7-16.9 N•m).
25. Apply thread sealant paste to threads of tee fitting
(6). Install tee fitting with safety valve (7) into
compressor output. Use a 11/16 in. wrench and a
9/16 in. backup wrench to attach the braided hose
from the air tank to the compressor.
14
332230R
LL200 Compressor Installation
26. Remove plug from compressor case. Install oil
breather (1c).
28. Before operation, ensure oil is visible on threads of
fill port. If not full, fill with included oil until visible on
threads.
NOTICE
Failure to properly fill compressor with oil can result in
failure and/or severe or catastrophic damage to the
compressor.
29. Reconnect spark plug wire.
27. Install air filter, hand tighten.
332230R
15
LL200 Compressor Installation
Bead Tank Mounting
1. Place bead tank on supporting base with outlet fittings facing compressor.
3. Install 36 in. nylon air line (dd) from top of regulator
to swivel fitting on top of bead hopper. Cut air line to
desired length. Push air line into fitting until end
touches bottom of fitting.
NOTE: Position handle to best suit filling needs.
Loosen bolt (aa) to help swivel, then retighten.
dd
aa
ti20704a
ti21195a
2. Place clamping band around tank and secure with
mounting hardware shown below. Tighten until
there is no movement between clamp and bead
tank.
ti21193a
NOTE: The flats on the clamp are not intended to
touch the hopper bracket when tightened.
16
332230R
LL250 Pressurized Bead System Kit 25R270
LL250 Pressurized Bead System Kit 25R270
Assemble Compressor Mounting
and Drive Components
4. Loosely install two screws (M) and two locknuts (N)
through bottom of frame mount. Use 9/16 in. wrench
to fully tighten.
M
1. Use rubber mallet or wood block to position right
frame mount (L) flush to LL250 frame.
N
ti20509a
5. Secure hydraulic lines with zip ties.
L
2. Place right frame mount (L) onto LL250 frame in
location shown below (approximately 1 in. from
cross member of LL250 frame). NOTE: To ensure
flush sitting, scrape frame free of any raised debris
on frame surface.
ti20507a
6. Position left frame mount (W) on LL250 frame.
Remove any zip ties in the way. Use a rubber mallet
to tap into place if needed.
Inches
Centimeter
ti20511a
L
3. Cut any existing tie wraps that interfere (they will be
replaced later with new tie straps).
W
ti20501a
7. Make sure left and right frame mounts are aligned.
The left leg should mirror the right leg location from
LL250 frame cross member.
ti20512a
332230R
17
LL250 Pressurized Bead System Kit 25R270
9. Assemble hopper bracket (X) and base (Y) with
hardware provided. Install carriage bolts with the
heads facing the paint tanks. Use 9/16 in. wrench to
tighten bolts.
Inches
Centimeter
ti20502a
8. Use 9/16 wrench to tighten bottom screws (M) to
hardware shown.
M
ti24390a
2.674"
10. Install plastic end caps (Z) into frame. Use rubber
mallet to pound end caps into place.
ti20500a
Z
ti20884a
18
332230R
LL250 Compressor Installation
LL250 Compressor Installation
Tools Needed: 2.5 mm Allen wrench, 4.0 mm Allen wrench,
1/4 in. Allen wrench, 7/16 in. wrench, 9/16 in. wrench, 11/16 in.
wrench, T-20 Torx bit, rubber mallet, Phillips screwdriver.
5. Using a 9/16 in. wrench and screws, mount the air
tank to the new air tank bracket.
Replacing the compressor requires pulling on the
starting rope. To help prevent entanglement, pinching,
and potentially serious injury from an unexpected
start-up, turn engine off, remove key and disconnect
the battery cable prior to compressor replacement.
1. Turn unit OFF and remove key. Let unit cool prior to
working on it.
2. Disconnect battery cable.
3. Perform Pressure Relief Procedure page 6.
4. Using bolts, plus lock nuts, install air bracket.
6. Using T-20 star bit, remove fan grill from shroud.
Save screws, nuts, and washers for reattachment.
332230R
19
LL250 Compressor Installation
7. Locate belt shroud. Loosen screw (A) and lift belt
shroud (B).
NOTE: Prior to step 14, secure nuts to back of pulley
with piece of duct tape will assist with installation.
14. Put belt shroud down, install shaft coupler (5) onto
pulley with two shoulder screws (18) and serrated
nuts (19). Position slot on back of pulley up and
move serrated nut with finger to accept shoulder
bolt threads. Tighten using shoulder bolt by hand
until the teeth on the serrated nut catch the
aluminum on the fan. Using a 1/4 in. Allen wrench,
torque to 16-18 ft-lb (21-24 N•m).
8. Using a 1/4 in. Allen wrench, remove shoulder bolts
and serrated nuts securing existing coupler plate.
NOTE: Do not use ball end Allen wrenches, as they
may break and become stuck in the set screws.
9. Loosen set screws on pulley. Lift engine to provide
slack for the belt and remove old pulley (X).
10. File any rough spots on the pump shaft key.
11. Slide new pulley on to the pump shaft. Pump shaft
must extend 0.125-0.225 in. (3.175-5.73 mm)
beyond the face of the pulley. The pump shaft is the
pilot for the coupler adapter.
12. Torque pulley set screws to 58-62 in-lb (6.6-7 N•m).
13. Install belt on pulley. Refer to Ground Drive Belt
Replacement in your striper repair manual for
additional instructions and belt tension
recommendations.
20
332230R
LL250 Compressor Installation
15. Use existing screws, nuts, and washers to install fan
grill (FF) back onto bet shroud. Do not over-tighten
screws. Make sure fan grill protrudes out; not into
the belt shroud.
332230R
16. Remove two existing bolts and washers from striper
frame. Install compressor bracket with three tabs
facing towards fan grill using existing washers and
bolts. Center coupler mounting plate horizontally in
slot, then tighten the two mounting screws to 23-27
ft-lb (31-37 N•m).
21
LL250 Compressor Installation
17. Place drop of medium strength thread locker on the
threads of each set screw. Using a 2.5 mm and a
4.0 mm Allen wrench, screw the set screws into the
shaft collar far enough so that the shaft collar can
slide on the compressor shaft sleeve. Rotate the
shaft collar so the pin faces up. Align the shaft collar
pin with the compressor shaft keyway as shown.
Slide the shaft collar onto the compressor shaft, pin
first.
NOTICE
Performing steps 19 through 23 out of order, or
incorrectly, may cause excessive side loading on the
compressor crankshaft and could cause a premature
failure of the compressor.
19. Slide the compressor onto the coupler mounting
plate until the face of the compressor is flush with
the compressor bracket. Rotate the compressor 90
degrees clockwise so that the set screw access is
accessible.
18. Using a long screw driver, slowly rotate the fan
pulley. With the keyway of the coupler mounting
plate facing up, place the key into the shaft keyway
with the key slid to the end of the shaft keyway (as
shown). A light tap with a rubber mallet may be
needed to ensure the key seats completely.
22
332230R
LL250 Compressor Installation
20. Use two carriage bolts (8), two washers (9), and two
nuts (16) in opposing holes (180 degrees apart) to
tighten the compressor to the compressor bracket.
21. Using a long screw driver, slowly rotate the fan
pulley until the two M8x10 set screws appear in the
set screw access. Torque the set screws to 150-160
in. lb (16.9-18 N•m). Again, slowly rotate the fan
pulley until the single M5x8 set screw appears in the
access and tighten it to 37-42 in. lb (4-4.7 N•m).
NOTE: Do not use ball end Allen wrenches, as they
may break and become stuck in the set screws.
22. Remove two carriage bolts, two washers, and two
nuts in opposing holes (180 degrees apart), and
rotate the compressor counterclockwise 90 degrees
back to the upright orientation.
332230R
23
LL250 Compressor Installation
23. With the compressor secured to the coupler
mounting plate, slightly loosen the two mounting
screws between the frame and bracket. Install all
four carriage bolts (9), washers (10), and lock nuts
(11), and torque to 150-160 in. lb (16.9-18 N•m).
Re-tighten the two mounting screws to 23-27 ft. lb
(31-37 N•m).
25. Apply thread sealer to threads of tee fitting (6).
Install tee fitting with safety valve (7) into
compressor output. Use a 11/16 in. wrench and a
9/16 backup wrench to attach the braided hose from
the air tank to the tee.
26. Remove plug from compressor case. Install oil
breather (1b).
24. Install compressor guard using three screws (14),
lock washers (15), and flat washers (16). Torque to
130-150 in. lb (14.7-16.9 N•m).
24
332230R
LL250 Compressor Installation
27. Install air filter. Hand tighten.
28. Before operation, ensure oil is visible on threads of
fill port. If not full, fill with included oil until visible on
threads.
NOTICE
Failure to properly fill compressor with oil can result in
failure and/or severe or catastrophic damage to the
compressor.
29. Reconnect the battery.
332230R
25
Maintenance
Maintenance
Routine maintenance is important to ensure proper
operation of your compressor. Maintenance includes
performing routine actions to keep your compressor in
operation and prevent trouble in the future.
Activity
Replace air filter
Change oil*
Interval
Every 200 hours, or as needed
After first 50 hours, then every 200 hours or three months
* Drain oil by siphoning from fill port. Use approximately 4 fl. oz
of SAE 30W air compressor oil. Proper oil level is attained when
oil just begins to drip over the edge of the fill port as shown
below.
Recycling and Disposal at End of Life
At the end of the product’s useful life, dismantle and
recycle it in a responsible manner.
Dismantle and recycle:
•
Preparation:
•
•
Perform the Pressure Relief Procedure page 6.
Drain and dispose of fluids according to applicable
regulations. Refer to the material manufacturer’s
Safety Data Sheet.
•
•
Remove motors, circuit boards, displays, and other
electronic components. Recycle according to
applicable regulations.
Do not dispose of electronic components with
household or commercial waste.
Deliver remaining product to a recycling facility.
California Proposition 65
WARNING: This product can expose you to chemicals known to the State of California
to cause cancer and birth defects or other reproductive harm. For more information
go to www.P65Warnings.ca.gov.
26
332230R
Maintenance
Bead Tank Mounting
1. When only one bead tank is being installed, it
should be placed on the side of the frame furthest
from the compressor to best distribute weight.
3. Place clamping band around tank and secure with
mounting hardware shown below. Tighten until
there is no movement between clamp and bead
tank. NOTE: The flats on the clamp are not intended
to touch when hopper bracket is tightened.
ti24485a
NOTE: Position handle to best suit filling needs.
Loosen bolt (AA) to help swivel, then retighten.
ti24483a
2. Place bead tank on supporting base with outlet fittings facing compressor.
AA
ti20704a
4. Install 36 in. nylon air line (DD) from top of regulator
to swivel fitting on top of bead hopper. Cut air hose
to desired length. Push air line into fitting until end
touches bottom of fitting.
DD
ti20493a
332230R
27
Operation
Operation
Charging Air Tank
Setting Bead Hopper Pressure
1. Start engine and engage clutch. Compressor is now
engaged.
The pressure regulator valve (5) controls pressure sent
from the air tank to the bead tank. The regulator is set to
0 pressure from the factory.
2. If compressor is not needed for a job, move compressor bypass switch (9) to horizontal ON position.
Compressor is now exhausting air into atmosphere.
8
9
ti21074a
ti21081a
3. Move compressor bypass switch (9) to vertical OFF
position to charge air pressure tank. Air tank will
continue to charge to 80 psi (5.5 bar, 55 MPa) then
cycle between 60-80 psi (4.1-5.5 bar, 41-55 MPa).
1. Before charging bead tank, confirm that bead tank
lid is fully secured and beads have been loaded into
tank.
2. To increase pressure, pull knob on pressure regulator valve (5) out and turn counter-clockwise. Watch
bead tank gauge (4) pressure and continue turning
valve until desired pressure is met.
4
5
ti21073a
8
9
ti21083a
ti21082a
4. See bead tank gauge (4) to read air tank pressure.
Pressure from air tank is used to open bead valves
at bead gun.
4
3. See bead flow chart to find proper settings for your
application.
4. Various orifices can be used in gun to obtain different flow rates in conjunction with bead tank pressure. See Determining Bead Application
Pressure page 30.
ti21079a
28
332230R
Operation
Bead Timing With Gun
1. Use air flow restrictor valves to help time the opening and closing of the bead guns to best match the
start and stop of paint lines.
2. Valve (X) is exhausting air and will control the timing
end of the bead application. Valve (Y) is sending air
to the gun and will control the timing of the start of
the bead application.
3. Turning the valve clockwise will delay gun opening/closing time. Turning the valve counter-clockwise will speed up gun opening/closing time.
NOTICE
Never store glass beads in tank between jobs. Begin the
day with moisture-free beads. Moisture will cause glass
beads to resist flow or solidify over time.
If moisture or condensation is present on tank interior,
leave lid open until dry. When operating without the bead
system, always leave the moisture drain valve open.
To air tank
X
Exhaust
ti21326a
Y
332230R
To
bead gun
29
Determining Bead Application Pressure
Determining Bead Application Pressure
The table below lists bead delivery rates for 4 inch (10
cm) lines with standard size highway beads.
2. Identify what the required bead delivery rate is in job
specifications.
•
Wider lines use multiples of 4 in. to determine bead
delivery.
3. Under bead gun nozzle size, find nearest value
compared to Step 2.
•
Larger beads reduce flow rates, so a larger nozzle
and higher pressure may be required.
4. Match pressure needed to Step 3. Set air regulator
to this pressure.
•
Always verify flow rates with a stopwatch and a
scale for weight.
† EXAMPLE:
To determine application pressure, follow steps 1 - 4
below:
1. Determine speed the machine will travel when
applying line.
Step 1
b. At 4 mph and 6 lb/gal with 0.281 nozzle set tank
pressure to 10 psi.
c.
Step 2
For 8 in. width, multiply weight/min value (7.1) x
2 and for 12 in. width x 3.
Step 3
mph
2
3
4
5
6
7
8
Bead Delivery Requirement (4 in.)
6 lb/gal
8 lb/gal
lb/min
lb/min
3.6
4.7
5.3
7.1
† 7.1
9.5
8.9
11.9
10.7
14.2
12.4
16.6
14.2
19
Step 1
Step 2
Step 3
Bead Delivery Requirement (10 cm)
720 gram/liter
960 gram/liter
lb/min
lb/min
3.6
4.7
5.3
7.1
† 7.1
9.5
8.9
11.9
10.7
14.2
12.4
16.6
14.2
19
Nozzle Size
Speed
Speed
mph
2
3
4
5
6
7
8
30
a. At 4 mph and 6 lb/gal with 0.234 nozzle set tank
pressure to 15 psi.
Step 4
Nozzle Size
0.234
lb/min
4
6
†7
9
11
13
16
0.234
lb/min
4
6
†7
9
11
13
16
0.281
lb/min
5
†7
9
11
14
16
19
Pressure Needed
psi
5
10
15
20
25
30
35
Step 4
0.281
lb/min
5
†7
9
11
14
16
19
Pressure Needed
psi
5
10
15
20
25
30
35
332230R
Determining Bead Application Pressure
Filling Bead Hopper
1. Move compressor bypass switch (9) to horizontal
position to disengage compressor or turn engine off.
ti21074a
9
2. Release pressure on bead tank to 0 psi (0 bar, 0
MPa). Turn pressure relief valve (8) to vertical position and watch bead tank pressure gauge (3) until
pressure reads 0 psi (0 bar, 0 MPa). Do not use
safety valve (3) to release pressure from bead tank.
2
ti21077a
4. Place funnel (1) into opening. Pour beads into hopper. Beads should not be filled to a height higher
than shown in figure below. Bead level can be
viewed through tank wall if light is present.
1
ti21076a
3
8
ti21075a
ti21081a
5. Secure lid over opening and tighten wing nut until lid
is level with hopper.
3. Loosen wing nut (2) until it reaches end of threads.
If any remaining pressure is in bead tank, it will be
released through seal while wing nut secures lid to
hopper. Confirm pressure is at 0 psi (0 bar, 0 MPa)
and open lid.
ti21080a
332230R
31
Determining Bead Application Pressure
0 to 8 in. Line Setup
2 Tank 1 Gun Setup
For wider lines it may be necessary to mount bead gun
as shown below.
Connect “Y” fitting as shown below to allow two tanks to
flow into one gun.
ti20977a
8 - 12 in. Line Setup
ti21258a
32
332230R
Determining Bead Application Pressure
Double Drop Setup
Use a “Y” fitting to create a dual bead gun setup for double drop beads. Splice exit hose on bottom of air switch
and branch into both guns.
ti20564a
332230R
33
Parts - Model 25R268
Parts - Model 25R268
34
332230R
Parts - Model 25R268
Parts List - 25R268
Ref. Part
Description
Qty.
1
25R108 COMPRESSOR, oil
1
1a† 19B286 KIT, collar, shaft, Includes 1b, 1d,
1
1e, and 23
1b 25R109 COLLAR, shaft
1
1c† 25R114 BREATHER, oil
1
1d 25R110 SET SCREW, M5x8
1
1e 25R111 SET SCREW, M8x10
2
2
25P605 KEY, square, 3/16 x 1.34
1
3
25P599 BRACKET, air tank
1
4
25P600 BRACKET, compressor straight
1
5
25P602 COUPLER, mounting plate
1
6
124490 FITTING, tee, street
1
7
113769 VALVE, safety
1
8
164672 ADAPTER
1
9
17N821 BOLT, carriage
4
10
100527 WASHER, flat
4
11
111040 NUT, lock, insert, nylock, 5/16
4
12
25P598 GUARD, compressor
1
13 15H108 LABEL, safety, warning, pinch
2
14
108296 SCREW, mach, hex wash hd
3
15
100016 WASHER, lock
3
16
110755 WASHER, flt, 1/4 in.
3
18
126833 SCREW, shoulder, socket head
2
19
112958 NUT, hex, flanged, 3/8-16
2
20
111193 SCREW, cap flange hd
6
21
111192 SCREW, cap flange hd
2
22
101566 NUT, lock
11
23
113500 ADHESIVE, anaerobic
1
25
25R330 GASKET, adhesive, compression
1
27 194668 LABEL, notice, glass bead
1
31
16T580 BAND, clamping, bead tank
1
32
16T763 FRAME, tank, LL200, painted, left
1
33
16T762 FRAME, bead, tank, LL2200,
1
painted, right
35
16T629 TANK, bead, includes 67 & 68
1
36
111194 SCREW, cap flange hd
2
332230R
Ref.
38
39
41
Part
115087
121488
16T593
42
45
48
49
16T939
16U273
16T437
16R963
50
51
52
53
54
55
57
58
59
60
61
62
63*
64*
65*
66†
67
68
404989
16U273
16C394
16U025
16U788
189919
101962
16U205
125626
100023
125809
119400
16T829
115287
16U274
25R115
16T601
113755
Description
Qty.
PLUG, tubing
2
SCREW, hex hd, flanged
6
BRACKET, bead tank, LL200,
1
painted
HOSE, coupled
1
HOSE, pneumatic
1
FUNNEL, bead tank
1
KIT, accessory, bead gun, includes
1
63, 64, and 65
STRAP, tie
2
GRILL, fan guard
1
LABEL, safety, warning, entangle
1
TANK, pressure
1
LABEL, pressure
1
BLANK, label, kit
1
SCREW, set, sch, 1/4-20
2
PULLEY, fan w/ attachment holes
1
SCREW, hex hd, flanged
3
WASHER, flat
3
LUBRICANT, oil, synthetic
1
SEALANT, pipe, stainless steel
1
HOSE, bead, 3/4 in., clean
2
FITTING, Y tube
1
HOSE, pneumatic
1
FILTER, air, compressor
1
LID, bead tank
1
O-RING
1
 Replacement warning labels may be ordered free of
charge.
* Included in set 16R963
 Parts included in set 19B286
† Parts included in set 25R108
35
Parts - Model 25R270
Parts - Model 25R270
36
332230R
Parts - Model 25R270
Parts List - Model 25R270
Ref. Part
Description
1
25R108 COMPRESSOR, oil
1a† 19B286 KIT, collar, shaft, Includes 1b, 1d,
1e, and 22
1b 25R109 COLLAR, shaft
1c† 25R114 BRETHER, oil
1d 25R110 SET SCREW, M5x8
1e 25R111 SET SCREW, M8x10
2
25P603 BRACKET, air tank LL250
3
25P601 BRACKET, compressor 250
4
164672 FITTING, adapter
5
25P602 COUPLER, mounting plate
6
124490 FITTING, tee, street
7
113769 VALVE, safety
8
25P598 GUARD, compressor
9
17N821 BOLT, carriage
10
100527 WASHER, flat
11
111040 NUT, lock, insert, nylock 5/16
12 15H108 LABEL, safety, warning, pinch
14
108296 SCREW, mach, hex
15
100016 WASHER, lock
16
110755 WASHER, flat, 1/4 in.
18
126833 SCREW, shoulder, socket head
19
112958 NUT, hex, flanged, 3/8-16
20
101566 NUT, lock
21
113500 ADHESIVE, anaerobic
22
25R126 KEY, shaft
23
25R330 GASKET, adhesive, compresion
25 194668 LABEL, notice, glass bead
26
111192 SCREW, cap flange hd
27
111193 SCREW, cap, flange hd.
29
16T580 BAND, clamping, bead tank
30
16T698 FRAME, bead tank, painted,
LL250, left
31
125626 SCREW, hex hd, flanged
32
16T437 FUNNEL, bead tank
33
16T596 BASE, bead tank frame, LL250
332230R
Qty.
1
1
1
1
1
2
1
1
1
1
1
1
1
4
4
4
2
3
3
3
2
2
17
1
1
1
1
2
1
1
1
6
1
1
Ref. Part
Description
Qty.
34
16T697 FRAME, bead tank, painted,
1
LL250, right
35
16U327 GRILL, fan guard
1
36
16T594 BRACKET, bead hopper, LL250,
1
painted
38
111194 SCREW, cap flange hd
6
41
16U273 HOSE, pneumatic
1
42
115087 PLUG, tubing
2
43
16R963 KIT, accessory, bead gun, includes
1
63, 64, and 65
45
404989 STRAP, tie
2
50
16T939 HOSE, coupled
1
51
16T629 TANK, bead, includes 69 & 70
1
54
16U025 TANK, pressure
1
55 16U788 LABEL, pressure
1
56
189919 BLANK, label, kit
1
58
124258 BOLT, carriage
4
59
101962 SCREW, set, sch, 1/4-20
2
60
16U205 PULLEY, fan w/ attachment holes
1
61
125809 LUBRICANT, oil, synthetic
1
62
119400 SEALANT, pipe, stainless steel
1
63* 16T829 HOSE, bead, 3/4 in., clean
2
64* 115287 FITTING, Y tube
1
65* 16U274 HOSE, pneumatic
1
68† 25R111 FITTING, air compressor
1
69
16T601 LID, bead tank
1
70
113755 O-RING
1
 Replacement warning labels may be ordered free of
charge.
* Included in set 16R963
 Included in set 19B286
† Included in set 25R108
37
Graco Standard Warranty
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.
38
332230R
Graco Standard Warranty
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.
332230R
39
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.
This manual contains English. MM 332230
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2013, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revision R, November 2020

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