Graco 25U546 Manual Download Page 2

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Contents

3A9031A

Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Important Grounding Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Grounding Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Pails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Trigger Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Front Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Spray Tip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Battery Installation and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Prime/Spray Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Flush Storage Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Fill Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Fill Gun and Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

How to Spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Install Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Position Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Paint Stripe Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Spray Test Stripe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Stencil Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Spray Tip Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Tip Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Clear Tip Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Cleanup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Cleaning and Flushing Fluid Compatibilty . . . . . . . . . . . . . . . . . . . . . 28

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Mechanical/Fluid Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

California Proposition 65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Summary of Contents for 25U546

Page 1: ...547 25U548 3300 psi 228 bar 22 8 MPa Maximum Working Pressure Related Manuals Important Safety Instructions Read all warnings and instructions in this manual and related manuals before using the equipment Be familiar with the controls and the proper usage of the equipment Save these instructions Manual Description 311254 Gun 334599 Pump Use only genuine Graco replacement parts The use of non Graco...

Page 2: ... Spray Valve 15 Flush Storage Fluid 15 Fill Pump 17 Fill Gun and Hose 18 How to Spray 19 Install Gun 19 Position Gun 19 Paint Stripe Width 20 Spray Test Stripe 20 Stencil Spraying 21 Spray Tip Selection 21 Tip Selection 22 Clear Tip Clog 23 Cleanup 24 Cleaning and Flushing Fluid Compatibilty 28 Maintenance 29 Troubleshooting 30 Mechanical Fluid Flow 30 Electrical 33 Parts 34 Wiring Diagram 41 Tech...

Page 3: ... 9ah DCB548 54V 4ah 18V 12ah DCB612 60V 4ah 20V 12ah Related DEWALT Manuals Model Battery Voltage VDC Charger Voltage VAC 25U546 60 USA CA 120 USA CA 25U547 54 EMEA UK 230 EMEA UK 25U548 54 ANZ AP 230 ANZ AP Manual Description Region N463494 DEWALT DCB118 Fast Charger Manual USA CA N463510 N463511 DEWALT DCB118 QW Fast Charger Manual Part 1 and 2 EMEA N501136 DEWALT DCB118 XE Fast Charger Manual A...

Page 4: ...lly fit into one of the following 3 basic types Grounding Wire and Clamp Required Type of Flushing or Cleaning Material FLAMMABLE This type of material contains flammable solvents such as xylene toluene naphtha MEK lacquer thinner acetone denatured alcohol and turpentine The container label should indicate that this material is FLAMMABLE Use flammable materials outdoors or in a well ventilated are...

Page 5: ... the pump hose assembly spray gun and objects in and around the spray area shall be properly grounded to protect against static discharge and sparks Use Graco conductive or grounded high pressure airless paint sprayer hoses Verify that all containers and collection systems are grounded to prevent static discharge Do not use pail liners unless they are anti static or conductive Do not use a paint o...

Page 6: ... 8 MPa Always engage the trigger lock when not spraying Verify the trigger lock is functioning properly Verify that all connections are secure before operating the unit Know how to stop the unit and bleed pressure quickly Be thoroughly familiar with the controls EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury Always wear appropriate gloves eye protection and a respirator or mask w...

Page 7: ...a cloth moistened with water 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 Equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure and disconnect all power sources TOXIC FLUID OR FUMES HAZARD Toxic flui...

Page 8: ...ay Valve 4 Spray Gun Trigger 5 Filter 6 Spray Gun Trigger Lock 7 Siphon Hose 8 Drain Hose 9 Finger Guard 10 Pump 11 Battery 12 Park Brake 13 Front Wheel Lock Unlock 14 Adjustable Pail Holder 15 Adjustable Handle 16 Serial Label on front side 17 Pressure Gauge 18 Gun Retainer Knob 19 Grounding Wire and Clamp ...

Page 9: ...onductive hoses with a maximum of 300 ft 91 m combined hose length to ensure grounding continuity Spray gun Grounded through connection to a properly grounded fluid hose and pump Pails Flammable and oil based materials follow local codes and regulations Use only conductive metal pails placed on a grounded surface such as concrete Do not place pail on a non conductive surface such as paper or cardb...

Page 10: ... the trigger lock 3 Hold a metal part of the gun firmly to a grounded metal pail Trigger the gun to relieve pressure 4 Engage the trigger lock This equipment stays pressurized until pressure is manually relieved To help prevent serious injury from pressurized fluid such as skin injection splashed fluid and moving parts follow the Pressure Relief Procedure whenever striper is stopped and before str...

Page 11: ...hose is clogged or that pressure has not been fully relieved a VERY SLOWLY loosen the tip guard retaining nut or the hose end coupling to relieve pressure gradually b Loosen the nut or coupling completely c Clear hose or tip obstruction Trigger Lock Always engage the trigger lock when sprayer is stopped to prevent the gun from being triggered accidentally by hand or if dropped or bumped ti24607a ...

Page 12: ...ng nut with TSL Front Wheel Alignment 1 Loosen cap screw 2 Position front wheel left or right as necessary to straighten alignment 3 Tighten cap screw Gently push striper and let striper roll without holding on to the striper Note if striper rolls straight or veers right or left Repeat steps 1 and 2 until striper rolls straight ti6392a ...

Page 13: ...p must be pushed all the way into the tip guard Turn spray tip to push down c Turn the arrow shaped handle on the spray tip forward to the spray position 4 Screw spray tip assembly onto the gun and tighten 5 Return spray to holder 6 Place trigger guard in front of nut on gun holder Tighten knob To avoid serious injury from skin injection do not put your hand in front of the Spray Tip when installi...

Page 14: ...yer Remove and install Battery into the striper as follows 1 Remove the used Battery if in place 2 Install battery by aligning the battery packwiththe rails inside the sprayer and sliding it in until the battery pack is firmly seated Ensure that it does not disengage Replace and charge Battery only in a well ventilated area and away from flammable or combustible materials including paints and solv...

Page 15: ...t of test material in the system It is important that you flush this material from the striper before using it for the first time 1 When flushing with flammable materials follow Grounding Instructions page 9 2 Follow Cleaning and Flushing Fluid Compatibility page 28 3 Perform Pressure Relief Procedure page 10 4 Make certain ON OFF switch is OFF Power button is NOT illuminated when OFF a Separate d...

Page 16: ... pail partially filled with water or flushing fluid 5 Place Prime Spray valve in PRIME position 6 Install battery see Battery Installation and Removal page 14 7 Align setting indicator with a low setting on Pressure Control Knob 8 Turn ON OFF switch to ON position Power button is illuminated when ON ...

Page 17: ... Procedure page 10 then tighten all fittings If there are no leaks continue with the next step Fill Pump 1 Move siphon tube to paint pail and submerge siphon tube in paint 2 Turn ON OFF switch to ON position Power button is illuminated when ON 3 Wait to see paint coming out of the drain tube 4 Turn ON OFF switch to OFF position Power button is NOT illuminated when OFF NOTE Some fluids may prime fa...

Page 18: ...pray valve to SPRAY position e Press ON OFF switch to ON position Button is illuminated when ON 2 Trigger gun into waste pail until only paint comes out of the gun 3 Release trigger Engage trigger lock 4 Transfer drain tube to paint pail and clip to siphon tube 5 Return gun to gun holder NOTE When motor stops sprayer is ready to paint If motor continues to run sprayer is not properly primed repeat...

Page 19: ...ainst 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 position Place gun and related hardware on right hand side b Left side gun position Place gun and related hardware on left hand side ti30302a ti30303a ...

Page 20: ...g from storage or switching paints colors consult Cleaning and Flushing Fluid Compatibility page 28 Paint Stripe Width 1 Adjust gun up or down to change paint stripe width If desired width cannot be attained change tip Refer to Component Identification page 8 for proper tip for application Spray Test Stripe 1 Disengage trigger lock 2 Trigger gun and spray test pattern Slowly adjust pressure to eli...

Page 21: ...ty of the striper Use larger tip hole sizes with thicker coatings and smaller tip hole sizes with thinner coatings Tips wear with use and need periodic replacement Tip hole size controls flow rate the amount of paint that comes out of the gun Fan Width Fan width is the size of the spray pattern which determines the area covered with each stroke Hints Select a fan width best suited to the surface b...

Page 22: ...5325 4 10 LL5327 4 10 LL5329 4 10 LL5331 4 10 LL5333 4 10 LL5335 4 10 LL5355 4 10 LL5417 6 15 LL5419 6 15 LL5421 6 15 LL5423 6 15 LL5425 6 15 LL5427 6 15 LL5429 6 15 LL5431 6 15 LL5435 6 15 LL5621 12 30 LL5623 12 30 LL5625 12 30 LL5627 12 30 LL5629 12 30 LL5631 12 30 LL5635 12 30 LL5639 12 30 ti27606a in cm ti27505a in cm ti27506a in cm ti27507a in cm ti27508a ti27509a ti27510a ti27605a ...

Page 23: ... Tip Clog 1 Release trigger Engage trigger lock Rotate Spray Tip Disengage trigger lock Trigger gun at waste area to clear clog 2 Engage trigger lock Return Spray Tip to original position Disengage trigger lock and continue spraying ...

Page 24: ...alled Rac Guard and Rac Tip in flushing fluid See Cleanup page 24 8 Remove siphon tube set from paint and place in flushing fluid Use water or pump conditioner for water based paint and mineral spirits for oil based paint To avoid serious injury from fire and explosion when using flammable materials Do not spray solvents through the spray tip Always remove tip guard and spray tip before flushing C...

Page 25: ...Close prime valve 12 Hold gun against a grounded paint pail Disengage gun trigger lock 13 Gradually turn pressure control up until motor begins to drive pump Trigger gun until flushing fluid appears 14 Move gun to flushing pail hold gun against a grounded pail trigger gun to thoroughlyflushsystem Release trigger and engage trigger lock ti30115a ti30117a ...

Page 26: ...ime valve Trigger gun into flushing pail to purge fluid from hose Open prime valve 19 Install filter into filter bowl Make sure plastic center tube is tightened securely NOTICE DO NOT run pump without fluid flow Damage to packings can occur ti30118a ti30119a NOTICE If flushing with water do not leave water in striper for extended periods Flush again with Pump Armor and leave protective coating in ...

Page 27: ...lean Rac Tip Rac Guard and gasket with a soft bristle brush to prevent part failure due to dried materials Assemble parts and attach loosely onto gun 21 Wipe striper hose and gun with a rag soaked in water or mineral spirits ...

Page 28: ...e fluid such as water or mineral spirits Mineral 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 spirits Mineral spirits Change water base to oil base paint Warm soapy water then clean water Mineral spirits Mineral spirits Mineral spirits Change oil base t...

Page 29: ...through TSL fill point Daily or each time you spray Check sprayer stall With sprayer gun NOT triggered sprayer motor should stall and not restart until gun is triggered again If sprayer starts again with gun NOT triggered inspect pump for internal external leaks and check prime valve for leaks Every 1000 gallons 3785 liters Throat packing adjustment When pump packing begins to leak after extended ...

Page 30: ... then reinstall Intake valve ball and piston ball are not seating properly Remove intake valve and clean Check balls and seats for nicks replace if necessary See pump manual Strain paint before using to remove particles that could clog pump Fluid filter or tip filter is clogged or dirty Clean filter Prime valve leaking Follow Pressure Relief Procedure page 10 then repair prime valve Verify pump do...

Page 31: ... connecting rod assembly See pump manual Gears or drive housing damaged Inspect drive housing assembly and gears for damage and replace if necessary Excessive paint leakage into throat packing nut Throat packing nut is loose Remove throat packing nut spacer Tighten throat packing nut just enough to stop leakage Throat packings are worn or damaged Replace packings See pump manual Displacement rod i...

Page 32: ...control is ON Indicates incorrect voltage Replace battery with a charged battery Battery has reached end of life Replace the battery ON OFF switch light blinks three times when pressure control is ON Indicates battery temperature is too hot or too cold Allow battery to cool down or warm up to room temperature ON OFF switch light blinks four times when pressure control is ON Indicates locked rotor ...

Page 33: ...ions Make certain connector is clean and firmly connected Check pressure control Connect known good pressure control If the motor runs replace pressure control Check motor leads Make certain terminals are clean and firmly connected Check all wiring harnesses for pinched or severed wires power switch motor pressure control Repair wires or bring to Graco certified repair shop Sprayer will not shut o...

Page 34: ...A9031A Parts ES 500 Airless Line Striper Parts Ref Torque Ref Torque Ref Torque 80 90 in lbs 9 10 2 N m 25 35 in lbs 2 8 4 N m 17 23 ft lbs 23 31 N m 23 27 in lbs 2 6 3 1 N m 190 210in lbs 21 5 28 7 N m 2 6 9 3 8 ...

Page 35: ...udes 92 1 75 249232 HOSE 14 in x 3 ft 1 81 195134 SPACER ball guide 1 82 198891 BRACKET mounting 1 83 198931 BEARING 1 84 113961 SCREW cap hex hd 1 85 867517 SCREW hex head 3 8 16 x 3 5 4 86 111802 SCREW 4 89 17N536 HOLDER bucket 2 90 24Z284 BAR handle LL 1 91 113665 SCREW cap hex hd 1 92 114802 WIRE stop 1 93 119554 NUT lock nylon thin pattern 4 96 114271 STRAP hose wrap 1 97 125626 SCREW hex hd ...

Page 36: ... Motor Module Parts Ref Torque Ref Torque Ref Torque 140 160 in lbs 15 8 18 1 N m 10 20 in lbs 1 13 2 26 N m 23 27 in lbs 2 6 3 1 N m 25 35 in lbs 2 8 4 N m 8 10 in lbs 0 9 1 13 N m 40 50 in lbs 4 5 5 6 N m 1 5 3 6 4 7 ...

Page 37: ... LABEL front 1 53 19D345 LABEL side 1 54 20A554 KIT motor module includes 1 8 9 10 25 1 56 19D605 SWITCH power 1 56a O RING 1 56b NUT 1 59 19D571 SHELF motor 1 67 128795 SCREW mach pan hd torx 2 68 19D553 BRACKET adapter ES 500 1 69 102040 NUT lock 2 70 17C483 COVER pump rod 1 77 100422 WASHER lock 2 80 19D606 BATTERY COMPARTMENT includes 5 8 81 122 1 81 17R614 FASTENERS battery compartment 4 82 1...

Page 38: ...Parts 38 3A9031A Filter Manifold Parts Ref Torque Ref Torque Ref Torque Ref Torque 140 160 in lbs 15 8 18 1 N m 130 140in lbs 14 7 16 9 N m 48 72 in lbs 5 4 8 1 N m 1 7 8 ...

Page 39: ...ap tall manifold includes 18 18 15B071 INSERT filter tall 1 19 20A475 LABEL PC 1 21 17C725 INDICATOR control pressure 1 24 196181 NIPPLE 1 4 npsm x 1 4 npt 3 26 15E022 SEAT valve 1 27 187625 HANDLE valve drain 1 29 17D294 SPACER manifold 2 30 17C735 SCREW mach HWH 2 35 239914 VALVE drain includes 5 26 1 36 224807 BASE valve 1 38 20A556 KIT control pressure cordless includes 19 51 1 51 20A474 LABEL...

Page 40: ...er gun 1 25 15F213 BRACKET cable 1 70 126111 RETAINER Circle Clip external 8mm 1 72 17J407 BRACKET support gun 1 73 119647 SCREW cap socket flathead 2 77 188135 GUIDE cable 1 156 LL5317 TIP spray striping includes 157 1 LL5419 TIP spray striping includes 157 1 210 17H720 STRAP tie 5 in 3 157 243281 GASKET seal tip 5 pack included w 156 1 202 17J424 BAR height adjust ment assy includes 203 204 205 ...

Page 41: ...Wiring Diagram 3A9031A 41 Wiring Diagram ...

Page 42: ... 168 4 cm Handles Up 68 0 in 172 7 cm Width 26 0 in 66 0 cm Weight with battery 121 lbs 55 kg Noise dBa 70 psi 0 48 MPa 4 8 bar Sound pressure 90 dBa Sound power 100 dBa Vibration per ISO 5349 Left hand 98in s 2 2 5m s 2 Right hand 98in s 2 2 5m s 2 Materials of Construction Wetted materials on all models zinc and nickel plated carbon steel nylon stainless steel PTFE acetal leather UHMWPE aluminum...

Page 43: ...California Proposition 65 3A9031A 43 California Proposition 65 CALIFORNIA RESIDENTS WARNING Cancer and reproductive harm www P65warnings ca gov ...

Page 44: ...s 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 inci...

Page 45: ...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 ...

Page 46: ...46 3A9031A ...

Page 47: ...3A9031A 47 ...

Page 48: ...hanges at any time without notice Original instructions This manual contains English MM 3A9031 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2021 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revision A January 2022 ...

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