Graco 239-041 Operation manual

308–699
Rev. B
Supercedes Rev. A
First choice when
quality counts. 
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
KEEP FOR REFERENCE.
Read manual 308–61 1 for important
warnings and instructions.
Road Lazer
Second Color Kit
Model 239–041
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1997, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
7534B



Installation
Introduction
The Second Color Kit is designed to increase existing
Road Lazer System capability by adding an additional
pump and supporting accessories. The Second Color
Kit can be added to an existing Road Lazer with one or
two pumps.
Pressure Relief Procedure
WARNING
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally . Fluid
under high pressure can be injected through the
skin and cause serious injury . T o reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure in
your sprayer manual whenever you:
 are instructed to relieve the pressure,
 stop spraying,
 check or service any of the system equipment,
 or install or clean the spray tip.
1. Flush the system. See Flush System in manual
308–611.
2.
Relieve pressure. See Pressure Relief Proce -
dure
in manual 308–61 1.
General Instructions
The following paragraphs provide instructions for
installing the Second Color Kit components on the
Road Lazer Striper . Refer to Figs. 1 thru 4 for installa -
tion. See Fig. 5 for parts list. The schematics on pages
10 and 1 1 provide additional detail and orientation in -
formation for installation. Index numbers with an A are
kit parts. Other index numbers are parts for the Road
Lazer.
Installation of Pump, Fluid Filter, and
Paint Hose
1. See Figs. 1 and 2. Install kit pump (A01) by pla -
cing in open space in pump mount base (413) next
to installed pump. Attach with four capscrews
(A24) and four locknuts (A15).
2. Attach fluid filter assembly (A02) to pump nip -
ple (A23).
3. See Fig. 3. Connect one end of coupled hose
(A38) to swivel union (A04) on fluid filter
. Route
hose along protection tube (5) to second gun
(341). Use tie straps (A37) to secure hose to tube.
4. Remove spare pipe plug from second gun (341).
Attach hose to spare gun inlet using swivel union
(A04) and ball valve (A39).
Installation of Pump Hydraulic
Components
1. See Fig. 4. Install flow regulator (A26) on valve
manifold (84).
2. Remove pipe plug next to installed ball valve (91)
on top of manifold. Install kit ball valve (A27), pipe
elbow (A28), straight nipple (A30), and coupled
hose (A31).
3. Route and attach hose to connection at bottom of
pump.
4.
Install hydraulic hose from top of pump to hydraulic
reservoir . Remove existing pipe plug from street
tee (97) or elbow (102) on top of reservoir and
connect hose(A32).
Syphon Setup For 2 Pump Configuration
 See Figs. 1 and 3. Attach coupled hose (A20) from
paint syphon to inlet on pump using fitting (A13)
and clamp (A21).
One color setup: Attach both hoses to one suction
tube.
Two color setup:
Attach each hose to a single suc -
tion tube.
Syphon Setup For 3 Pump Configuration
 See Figs. 2 and 3. For 3 pump configuration, set -
up syphons as shown in Figs. 2 and 3.
Complete Installation
WARNING
For safe operation of this equipment , see
manual 308–61 1 for important warnings and
instructions.
1. After installing kit, flush system to prepare for
painting. See Flush System in manual 308–61 1.

 
Installation
AA
C
B
OR AB
C
D
D
7535B
Fig. 1
TWO COLOR
ONE COLOR
A23
413
A02
A01
A24
A15
Setup for 2 Pump Configuration
A38
A04
5, A37
341
A39
A38 REF

308-699
4
Installation
D
A
C
B
A
B
C
D
7536B
Fig. 2
Setup for 3 Pump Configuration
3 PUMP SYSTEM
5, A37
341
A04
A39
A38 REF
A23
413
A02
A01
A24
A15
A38
A04

308-699 5
Installation
7537B
Fig. 3
5
A04
A38
A37
341
Paint Hose, Syphon Setup, and Routing for 2 or 3 Pump System
(2ND PUMP)
A04
(3RD PUMP)



Installation
7538A
(PUMP 2) A26
84
A27 (PUMP 2)
A28
A30 A31
(PUMP 3) A26
(T O PUMP 2)
(T O PUMP 3)
97
A27 (PUMP 3)
(FROM PUMP 2 OR 3)
Hydraulic Components for 2nd or 3rd Pump Installation
91
Fig. 4
102
A29

308-699 7
Notes



Parts List
7539B
Fig. 5
A19
A18
A16
A21
A13
A14
A17
A11
A12
A33
1 PUMP CONFIG
2 PUMP CONFIG
A15
A01
A24
A21
A04
A03 A02
A05 A22A23
A09
A32
A06
A07
A08
A25
A10
84
A30
A28
A27
A26
A31 (REF)
A29
A31
333
339
341
A13
A34,A35,
or A36
A32
(REF)
A39
A38
A37
403
A20
413
A20 (REF)
A38
(REF)
A21
A13 A20
(REF)
(REF)
(REF)
91
97
102

 
Parts List
Second Color Kit Parts
Ref.
No. Part No. Description Qty
A01 238–349 PUMP
, paint 1
A02 238–782 FIL
TER, fluid, sst 1
A03 164–856
NIPPLE, reducing, 3/8 in. npt x 1
1/4 in. npt, 1–1 1/16 in. (43) mm) long
A04 207–123 UNION, swivel, 902
A05 102–814 GAUGE, pressure, fluid 1
A06 166–866 ELBOW
, 90  , sst, 1/4 npt x 1/4 npt, 1
1–1
1/32 in. (34 mm) long
A07 166–846 NIPPLE, 1/4 in. npt x 1/4 in. npsm, 1
1–3/16 in. (31 mm) long, sst
A08 220–285 CAP 1
A09 238–967 VAL
VE, ball 1
A10 191–731
PIPE, pump, extension 1
A11 113–606
TEE, 1 in., 1/2 npt 1
A12 113–561
PLUG, pipe, 1 in., 1/2 npt 1
A13 113–607
FITTING, barb 1 in., 1/2 npt 2
A14 191–641 CAP
, splash 1
A15 113–797 COLLAR, screw
, set 1
A16 176–684
ADAPTER, bung 1
A17 100–220 SCREW
, thumb, grade 5 1
A18 191–624 TUBE, suction 1
A19 191–635 STRAINER, inlet 1
A20 191–627 HOSE, suction 1
A21 101–818 CLAMP
, hose 2
A22 114–046 CHECK VAL
VE, 3/8 in. x 3/8 in., sst 1
A23 235–208
UNION, adapter , swivel, 1
3/8 in. npt(m) x 3/8 in. npsm(f)
A24 100–004 CAPSCREW , hex hd, grade 5 4
3/8–16 unc–2a, 1–1/4 in. (32 mm) long
A25 101–566 LOCKNUT , nylon, 3/8–16 4
A26 113–703 REGULATOR, hydraulic flow 1
A27 210–658 VAL
VE, ball 1
A28 165–472 ELBOW
, pipe, 90  ; 3/8 npt(f) 1
A29 150–286 ADAPTER 1
A30 110–311
NIPPLE, straight; 3/8–18 npt(f) x 1
3/4–16 unf
A31 191–645 HOSE, coupled, 24 in. 1
A32 191–647
HOSE, coupled, 27 in. 1
A33 114–304 ELBOW
, 1 in., 90 1
A34 054–163
TUBE, polyolefin, shrinkable x 8 in. 1
A35 054–747
TUBE, polyolefin, shrinkable x 8 in. 1
A36 054–748
TUBE, polyolefin, shrinkable x 8 in. 1
A37 108–774 STRAP
, tie 10
A38 191–239
HOSE, coupled, 1 1 ft 6 in. 1
A39 238–694 VAL
VE, ball 1
Road Lazer Parts
Ref.
No. Part No. Description Qty
84 192–045 MANIFOLD, valve 1
91 210–658 VAL
VE, ball 1
97 111–337
TEE, street, 3/4 npt–14 npt(f) 2
102 113–671 ELBOW
, 3/4–14 npt(f) 1
333 207–123 UNION, swivel, 90
, 3/8 in. npsm(f) x 1
3/8 in. npt(m)
339 238–694 VAL VE, ball 1
341 238–332 GUN, spray
, auto 2
See Manual 308–613 for parts
403 238–787 RESERVOIR, hydraulic 1
413 191–248
BASE, pump mount 1

308-699
10
Schematics
Paint hose connections
1
2
Electrical connector J6
to Programmable Skip–
line Controller
3
3
Solenoid air valves
4
4
A E D
BC
AB
CD
E
Paint gun (P1) Paint gun (P2)
Bead gun (B1) Bead gun (B2)
+ 12 Vdc
Paint Hose Connections
06266
B1
P2
1
1
1
Pneumatic lines
2

308-699 11
Schematics
7540A
T
o engine kill switch
T
o bead gun 1
T
o paint gun 2
T
o bead gun 2
T
o paint gun 2
T
o paint gun 1
From bead tank
From bead tank
T
o gun arm safety switch
From pump 2
From pump 1
From compressor
To valve pack
From pump 2 or 3
T
o pump 3
T
o pump 2
T
o pump1
To valve pack
To proximity sensor
T
o + battery post
T
o – battery post
T
o cooling fan
T
o engine switch
Main Harness 236–680
1
5
A38
Ref.
No. Part No. Description Qty.
A37
108–774 STRAP , tie 10
A38 191–239 HOSE, coupled, 1
1 1 ft, 6in.
1 1 13–486 CABLE, power 1
5 191–857 TUBE, protection 1
A37

308-699
12
Graco W arranty
Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the
date of sale by an authorized Graco distributor 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 accor -
dance 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 sub -
stitution
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
W ARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER W ARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED T O 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 reconnais -
sent
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 procedures concernées.
ADDITIONAL W ARRANTY COVERAGE
Graco does provide extended warranty and wear warranty for products described in the “Graco Contractor Equipment Warranty
Program”.
Graco Phone Number
TO PLACE AN ORDER , contact your Graco distributor , or call this number to identify the distributor closest to you:
1–800–367–4023 T oll Free
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.
Sales Offices: Atlanta, Chicago, Detroit, Los Angeles
Foreign Offices: Belgium, Canada, England, Korea, Switzerland, France, Germany , Hong Kong, Japan
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
http://www.graco.com
PRINTED IN U.S.A. 308–699A July 1997, Revised November 1997