Graco 308395D User's Manual
Contents
1. F 4l a A b 9 fL pla A Model 236864 Fic 2 Typical Installation Key A Hydraulic Control 236864 B Hydraulic Control 236865 C Hydraulic Return Line D Hydraulic Outlet 3 4 npsm A 1 1 4 npsm B E Return Line Shutoff Valve F Hydraulic Inlet 3 8 npsm A 3 4 npsm B G Supply Line Shutoff Valve H Pressure Gauge J Pressure Reducing Valve K Flow Control Valve L Hydraulic Supply Line use only Graco hydraulic power supply Hydraulic Fluid Control The hydraulic fluid control pro vides pressure regulation flow regulation and pump isolation See the Typical Installation as a guide For assistance in designing a system to suit your needs contact your Graco Representative 308395D Installation Model 236865 Pressure Regulation The hydraulic fluid control pres sure reducing valve J reduces the hydraulic oil pres sure to the operating pressure required for application Flow Regulation The hydraulic fluid control valve K limits the maximum amount of oil flow to the motor to keep the hydraulic motor within the recommended cycle rate limit This prevents pump runaway The limit on the Dyna Star is 60 cpm The limit on the Power Star is 66 cpm Pump Isolation The hydraulic fluid control A and B has ball valves on the supply and return sides of the mani fold The ball valves isolate the hydraulic fluid control and pump for servicing without stopping t2. manual where applicable FIRE AND EXPLOSION HAZARD When flammable fluids are present in the work area such as gasoline and windshield wiper fluid be aware that flammable fumes can ignite or explode To help prevent fire and explosion Use equipment only in well ventilated area Eliminate all ignition sources such as cigarettes and portable electric lamps Keep work area free of debris including rags and spilled or open containers of solvent and gasoline Do not plug or unplug power cords or turn lights on or off when flammable fumes are present Ground all equipment in the work area Use only grounded hoses 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 SKIN INJECTION HAZARD High pressure fluid from dispensing device 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 e Do not point dispensing device at anyone or at any part of the body e Do not put your hand over the fluid outlet e Do not stop or deflect leaks with your hand body glove or rag e Follow the Pressure Relief Procedure when you stop dispensing and before cleaning checking or servicing equipment Tighten all fluid connections before operating the equipment Check hoses and couplings daily Replace worn or dama
3. return line shutoff valve E first and slowly open the hydraulic supply shutoff valve G 3 Remove the cap on the pressure reducing valve to reveal the cap screw adjustment 4 Adjust the hydraulic inlet pressure from 50 to 1500 psi 0 3 to 10 5 MPa 3 to 105 bar with an allen wrench inserted in the regulator pressure control adjustment on the pressure reducing valve J Increasing the inlet pressure clockwise increases the pump outlet pressure Decreasing the inlet pres sure counter clockwise decreases the pump outlet pressure 5 Always use the lowest pressure possible to obtain the desired results This reduces pump wear Repair Shutdown a i Always shut off the supply line shutoff valve E first and then the return line shutoff valve G This is to prevent over pressurizing the reciprocator or its seals When starting the hydraulic system open the return line shut off valve G first See page 5 Repair There are two basic repairs to the hydraulic fluid control pressure control repair and flow control repair Pressure Control Repair 1 Relieve pressure see page 7 2 Remove the pressure reducing valve J 3 Clean the pressure reducing valve J with a com patible solvent 4 Install the pressure reducing valve in the control 5 Try the system with the clean valve Follow the Starting the Pump procedure on page 7 6 Ifthe control still does not regulate the pressure properly replace the va
4. to pump again If you suspect that the dispensing valve nozzle or hose is completely clogged or that pressure has not been fully relieved after following the steps above VERY SLOWLY loosen the hose end coupling and relieve pres sure gradually then loosen completely now clear the obstruction Emergency Stop Procedure Close the red marked supply line shutoff valve marked STOP Before Starting the Pump When starting up the hydraulic system open the return line shutoff valve E first 308395D Operation Hydraulic Fluid Level Check Check the hydraulic fluid level in the hydraulic power supply before each use and add fluid as necessary to fill the lines W the Pump e Never exceed 1500 psi 10 5 MPa 105 bar Maxi mum Hydraulic Pressure to the control e Never exceed 375 psi 2 6 MPa 26 bar Maximum Outlet Pressure from the control when used with a 1 4 1 Dyna Star pump e Never exceed 1500 psi 10 5 MPa 105 bar Maxi mum Outlet Pressure from the control when used with a 1 1 Power Star pump e Be sure all accessories added to the reciprocator power supply side of the control are capable of at least 1500 psi 10 5 MPa 105 bar maximum work ing pressure and all of those for the pump fluid out let side of the control have at least 375 psi 2 6 MPa 26 bar maximum working pressure for Dyna Star and 1500 psi 10 5 MPa 105 bar for Power Star 1 Turn on hydraulic power supply 2 Openthe
5. 10 10 Part 108537 112714 112567 112578 112581 112705 112707 112708 112715 113 Includes items 113a amp 113b Description VALVE ball HOSE coupled 3 ft GAUGE pressure fluid VALVE ball SWIVEL union 90 SWIVEL union 90 ADAPTER male ADAPTER male HOUSE couple 3 ft zi lt N e 4 4s fp S Ref 111 113 113a 113b Part 155494 160327 189837 119902 112712 110 104 110 Description Qty UNION swivel 90 1 UNION swivel 90 1 MANIFOLD 3 gpm includes 1 replaceable items 113a and 113b VALVE pressure reducing 1 VALVE flow regulating 3 gpm 1 308395D Model 236865 Hydraulic Fluid Control Ref 102 103 104 105 106 107 108 109 110 Part 108537 112567 112579 112580 112705 112706 112708 112709 112715 308395D Description VALVE ball GAUGE pressure fluid VALVE ball SWIVEL union 90 SWIVEL union 90 SWIVEL union 90 ADAPTER male ADAPTER male HOSE coupled 3 ft 2 lt N e n n zr Ref 111 112 113 113a 113b Part 112716 160327 189838 119903 112713 111 105 104 Includes items 113 113a amp 113b 103 Description HOSE coupled 3 ft UNION swivel 90 MANIFOLD 12 gpm includes items 113a and 113b VALVE pressure reducing VALVE flow regulating 12 gpm Parts 11 Technical Data Technical Data Hydraulic Fluid Controls Dyna Star Maximum fluid working pressu
6. AZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swal lowed e Head MSDSs to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines e Always wear chemically impermeable gloves when spraying dispensing or cleaning equipment 308395D 3 Installation Installation Grounding The equipment must be grounded to reduce the risk of static sparking and electric shock Electric or static sparking can cause fumes to ignite or explode Improper grounding can cause electric shock Grounding provides an escape wire for the electric current Pump use ground wire and clamp supplied Loosen grounding lug locknut W and washer V Insert one end of a 12 ga 1 5 mm minimum ground wire Y into the slot in lug Z and tighten the locknut securely Con nect the other end of the wire to a true earth ground Order Part No 237569 Ground Wire and Clamp Hydraulic Hoses and Fluid Outlet Hoses use only electrically conductive hoses Hydraulic Power Supply and Air Compressor follow manufacturer s recommendations Any pails used when flushing use only metal grounded pails when flushing Make firm metal to metal contact between a metal part of the dispense valve and the pail Use the lowest possible pressure FiG 1 308395D Typical Installation G J K
7. CULAR 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 dir
8. Instructions Hydraulic Fluid Controls 7 GRACO 308395D EN Regulates hydraulic pressure and flow when used with Graco s Dyna Star and Power Star hydraulic powered lubricant pumps For professional use only Model 236864 Used with Dyna Star 1500 psi 10 5 MPa 105 bar Maximum Working Pres sure 3 gpm 11 liters min Maximum Flow Rate Model 236865 Used with Power Star 1500 psi 10 5 MPa 150 bar Maximum Working Pres sure 12 gpm 45 liters min Maximum Flow Rate Model 236865 Head all warnings and instructions in this manual Save these instructions e Important Safety Instructions Hydraulic fluid controls are designed to control hydraulic fluids only in a hydraulic power system Any other fluids can cause unsafe operating conditions and results in component rupture fire or explosion which could result in serious injury including fluid injection t vono ON nia m Model 236864 PROVEN QUALITY LEADING TECHNOLOGY Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion 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
9. ectly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6928 or Toll Free 1 800 533 9655 Fax 612 378 3590 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 For patent information see www graco comvpatents Original instructions This manual contains English MM 308395 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 1994 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Revised November 2012
10. ged parts immediately 2 308395D Warnings EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury e Do not operate the unit when fatigued or under the influence of drugs or alcohol e Do not exceed the maximum working pressure or temperature rating of the lowest rated system com ponent 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 manu facturer 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 Houte 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 TOXIC FLUID OR FUMES H
11. he hydraulic power source Installation Installation Notes NOTICE The hydraulic supply system must be kept clean at all times to reduce the risk of damaging the reciprocator hydraulic power supply e Blow out all hydraulic lines with air flush thoroughly with solvent and then blow out the air again before connecting the lines to the reciprocator Hydraulic Power Supply To reduce the risk of over pressurizing the hydraulic reciprocator which could cause a rupture and serious injury including fluid injection the hydraulic power must have a means to limit the incoming fluid flow to the reciprocator to a maximum of 3 gpm 11 liter min at 1500 psi 10 5 MPa 105 bar for the Dyna Star and 10 gpm 37 liter min at 1500 psi 10 5 MPa 105 bar for the Power Star Hydraulic Components e Always turn off the supply side valve G to avoid possible serious injury or component damage See the Typical Installation on page 5 Maximum Working Pressure of Accessories To reduce the risk of serious injury including fluid injection and splashing in the eyes or on the skin which may be caused if a component ruptures all accessories added to the reciprocator power supply side must have at least 1500 psi 10 5 MPa 105 bar maximum working pressure and those to the pump fluid outlet side must have at least a 375 psi 2 6 MPa 26 bar maximum working pressure for Dyna Star and 1500 psi 10 5 MPa 105 bar for the P
12. lve Flow Control Repair js 2 Helieve pressure see page 7 Remove the flow control valve K Clean the flow control valve K with compatible sol vent Install the flow control valve in the control Try the system with the clean valve Follow the Starting the Pump procedure on page 7 If the control still does not control the flow properly replace the valve 308395D Troubleshooting Troubleshooting V C VR a MEME UM No pressure on gauge or low pres Hydraulic power supply malfunction Adjust the hydraulic power supply If sure on gauge or mis adjustment the problem remains refer to the hydraulic power supply instruction manual Pressure reducing valve is backed Adjust the pressure reducing valve out Can t adjust pressure with the pres Clogged valve Clean the pressure reducing valve SHIETSOUCINO Waive Insufficient hydraulic power supply Adjust the hydraulic power supply pressure pressure If problem remains refer to the hydraulic power supply instruction manual Gauge will not re zero with the Leak in the supply line shutoff valve Open the return line shutoff valve hydraulic supply and return line G E to remove pressure shutoff valves closed Damaged gauge Replace gauge Pump runs away Contaminated flow control valve Hemove and clean the flow control valve 308395D 9 Parts Parts Model 236864 Hydraulic Fluid Control Ref 102 103 104 105 106 107 108 109 1
13. ower Star e Do not kink hoses Adjust swivel connections if nec essary e Always use permanently coupled electrically con ductive hoses e Refer to the application data from Graco to make determinations as to the location and height to mount the control Recommended Hydraulic Oil Use Graco approved Hydraulic Oil or a premium ISO grade 46 petroleum based hydraulic oil containing rust and oxidation inhibitors and anti wear agents e Before using any other type of oil in this control contact your Graco distributor Unauthorized use of lesser grade oil or substitutes may void the warranty e See Technical Data on page 12 for hydraulic oil working temperatures 308395D Operation Pressure Relief Procedure Follow the Pressure Relief Procedure whenever you see this symbol Sn Vii a W se Va 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 1 Close the supply line shutoff valve G and then return line shutoff valve E 2 Hold open the dispensing valve to relieve pressure 3 Place a container under the drain valve to catch any drainage Open the pump outlet drain valve 4 Leave the drain valve open until you are ready
14. re 1500 psi 0 5 MPa 105 bar Pressure adjusting range 500 1500 psi Co 5 10 5 MPa 35 105 bar Flow setting Tim Maximum fluid temperature 130 F Wetted materials O O x A e o 11 Ib Aluminum steel nitrile Sound Pressure lt 70 dB A Dimensions Weight See Below Hydraulic Fluid Controls Power Star Maximum fluid working pressure Pressure adjusting range Flow setting 500 psi 10 5 MPa 105 bar 00 1500 psi 2 0 10 5 MPa 20 105 bar 2 gpm 45 Ipm U C2 O O 22 lb 10 kg Wetted materials Aluminum steel nitrile Sound Pressure 70 dB A Dimensions Dimensions 12 D G 3 x 0 406 in Use 3 8 in 9 mm screws 3 x 0 406 in Use 3 8 in 9 mm screws 1 875 in 5 in 47 63 mm m 5 25 mm in 4 25 in 53 97 107 95 mm l Y uu I 4 25 in 107 95 mm Model 236864 Model 236865 A fd 5 25 133 35 mm 308395D Notes 308395D Notes 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
15. 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 PARTI
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