Graco 236864 User manual

Instructions

Hydraulic Fluid

Controls 308395D

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

Important Safety Instructions

Read all warnings and instructions in this

manual. Save these 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.

Model 236865

Model 236864

Warnings

2308395D

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 manual where

applicable.

WARNING

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.

• Do not point dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• 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 damaged parts immediately.

Warnings

308395D 3

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 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.

• 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.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swal-

lowed.

• Read MSDSs to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.

WARNING

Installation

4308395D

Installation

Grounding

Pump: use ground wire and clamp (supplied). Loosen

grounding lug locknut (W) and washer (V). Insert one

end of a 12 ga (1.5 mm2) 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.

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.

FIG. 1

ZV W

Installation

308395D 5

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.

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 the hydraulic

power source.

FIG. 2: Typical Installation

Model 236865

Model 236864

Installation

6308395D

Installation Notes

• 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

Hydraulic Components

• Do not kink hoses. Adjust swivel connections if nec-

essary.

• Always use permanently coupled electrically con-

ductive hoses.

• 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.

• 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.

• See Technical Data on page 12 for hydraulic oil

working temperatures.

NOTICE

The hydraulic supply system must be kept clean at all

times to reduce the risk of damaging 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™.

• 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 Power-Star™.

Operation

308395D 7

Operation

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever

you see this symbol.

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 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.

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.

Starting the Pump

• Never exceed 1500 psi (10.5 MPa, 105 bar) Maxi-

mum Hydraulic Pressure to the control.

• 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.

• 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.

• 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. Open the 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.

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.

Repair

8308395D

Shutdown

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. If the control still does not regulate the pressure

properly, replace the valve.

Flow Control Repair

1. Relieve pressure, see page 7.

2. Remove the flow control valve (K).

3. Clean the flow control valve (K) with compatible sol-

vent.

4. Install the flow control valve in the control.

5. Try the system with the clean valve. Follow the

Starting the Pump procedure on page 7.

6. If the control still does not control the flow properly,

replace the valve.

Troubleshooting

308395D 9

Troubleshooting

Problem Cause Solution

No pressure on gauge, or low pres-

sure on gauge

Hydraulic power supply malfunction

or mis-adjustment

Adjust the hydraulic power supply. If

the problem remains, refer to the

hydraulic power supply instruction

manual.

Pressure reducing valve is backed

out

Adjust the pressure reducing valve.

Can’t adjust pressure with the pres-

sure reducing valve

Clogged valve Clean the pressure reducing valve.

Insufficient hydraulic power supply

pressure

Adjust the hydraulic power supply

pressure. If problem remains refer

to the hydraulic power supply

instruction manual.

Gauge will not re-zero with the

hydraulic supply and return line

shutoff valves closed

Leak in the supply line shutoff valve

(G)

Open the return line shutoff valve

(E) to remove pressure.

Damaged gauge Replace gauge.

Pump runs away Contaminated flow control valve Remove and clean the flow control

valve.

Parts

10 308395D

Parts

Model 236864 Hydraulic Fluid Control

113a

113b

111

105

104

108

109

106

102

112

107

113 Includes items

113a & 113b

103

1110

110

103

Ref. Part Description Qty.

102 108537 VALVE, ball 1

103 112714 HOSE, coupled, 3 ft 2

104 112567 GAUGE, pressure, fluid 1

105 112578 VALVE, ball 1

106 112581 SWIVEL, union, 90° 1

107 112705 SWIVEL, union, 90° 1

108 112707 ADAPTER, male 1

109 112708 ADAPTER, male 1

110 112715 HOUSE, couple, 3 ft 2

111 155494 UNION, swivel, 90° 1

112 160327 UNION, swivel, 90° 1

113 189837 MANIFOLD, 3 gpm, includes

replaceable items 113a and 113b

113a 119902 VALVE, pressure reducing 1

113b 112712 VALVE, flow regulating, 3 gpm 1

Ref. Part Description Qty.

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