Graco Power-Star 236754 User manual

Instructions - Parts List

Power-Star™308391K

Used to pump high volumes of petroleum and synthetic based oils. For professional use

only.

Model No. 236754, Series A

1:1 Ration Universal Pump and Reciprocator

Model No. 236752, Series A

Reciprocator Only

1500 psi (10 MPa, 103 bar) Maximum Hydraulic Input Pressure

1500 psi (10 MPa, 103 bar) Maximum Fluid Outlet Pressure

Important Safety Instructions

Read all warnings and instructions in this

manual. Save these instructions.

This pump is designed to be used only in pumping

non-corrosive and non-abrasive oils and lubricants.

Any other use of the system can cause unsafe

operating conditions and result in components

rupture, fire, or explosion which can cause serious

injury, including fluid injection.

2308391K

Contents

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Pump Accessories . . . . . . . . . . . . . . . . . . . . . . . 5

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Hydraulic Power Supply . . . . . . . . . . . . . . . . . . . 6

Hydraulic Components . . . . . . . . . . . . . . . . . . . . 7

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Pressure Relief Procedure . . . . . . . . . . . . . . . . . 8

Before Starting the Pump . . . . . . . . . . . . . . . . . . 8

To Start the Pump . . . . . . . . . . . . . . . . . . . . . . . . 8

Shutdown and Care . . . . . . . . . . . . . . . . . . . . . . 9

Emergency Stop Procedure . . . . . . . . . . . . . . . . 9

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Displacement Pump . . . . . . . . . . . . . . . . . . . . . 14

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . 20

Warnings

308391K 3

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

4308391K

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

swallowed.

• 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.

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.

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 eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer

WARNING

Installation

308391K 5

Installation

Pump Accessories

Suction Tube Kit: A suction tube kit is available for

siphoning from 55 gallon containers.

Intake Tube: To install, apply PTFE tape to the female

threads at the top of the tube (Q). Screw the tube tightly

into the intake housing of the stubby pump.

Low-Level Cutoff Valve: To install, screw the low-level

cutoff valve into the bottom of the pump intake tube or

the suction tube. This valve closes the pump intake

when the fluid level is low, causing the pump to stall to

avoid running all day.

Pump Outlet Drain Valve: Install a drain valve (D) close

to the pump fluid outlet assist in relieving fluid pressure

in the pump, hose, and dispense valve when the pump

is shut off.

Thermal Relief Kit: Install a Thermal Relief Kit (T) at the

pump fluid outlet.

Grounding

Pump: Use a ground wire and clamp. Remove the

ground screw (Z) and insert through the eye of the ring

terminal at end of ground wire (Y). Fasten the ground

screw back onto the pump and tighten securely. Con-

nect the other end of the ground wire to a true earth

ground. (FIG. 1)

Hydraulic and fluid hoses: Use only electrically con-

ductive hoses.

Hydraulic power supply: Follow manufacturer’s recom-

mendations.

Any pails used when flushing: Use only metal,

grounded pails when flushing. Make firm metal-to-metal

contact between the metal part of the dispense valve

and the pail. Use the lowest possible pressure.

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 by component ruptures, all

accessories added to the reciprocator power supply

side of the pump fluid outlet side must have at least a

1500 psi (10 MPa, 103 bar) maximum working

pressure.

NOTICE

A pump outlet drain valve is required in the system.

This valve helps relieve pressure in the

displacement pump and hose when shutting down

the system and in case of a clogged outlet hose.

Install the valve hose close the pump outlet.

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

Installation

6308391K

Key:

A Hydraulic Control (See manual 308395)

B Porous Plug (weep tube optional)

C Fluid Dispense Outlet

D Drain Valve (required)

E Hydraulic Return Line

F Hydraulic Outlet, 1 1/4 npt

G Return Line Shutoff Valve

H Hydraulic Inlet, 3/4 npt

J Hydraulic Supply Line Shutoff Valve

K Pressure Gauge

L Pressure Reducing Valve

M Flow Control Valve

N Hydraulic Supply Line (Use only Graco Hydraulic power

supply)

P Dispensed Material Supply Suction Hose Kit

R Ground Wire (required)

S Wall Mounting Bracket (See manual 308394)

T Thermal Relief Kit (required)

NOTE: The installation shown in FIG. 2 is only a guide.

For assistance in designing a system to suit your needs.

Contact your Graco representative.

Mount the pump to suit the type of installation planned.

Hydraulic Power Supply

To reduce the risk of damaging the hydraulic power sup-

ply, blow out all hydraulic lines with air, flush thoroughly

with solvent, and then blow out with air again before

connecting the lines to the motor.

Always plug the hydraulic inlets, outlets, and lines when

disconnecting them to avoid introducing dirt and other

contaminants to the system.

Carefully follow the manufacturers recommendations on

reservoir and filter cleaning, and periodic changes of the

hydraulic fluid.

FIG. 2: Typical Installation

Installation

308391K 7

Hydraulic Components

Drain Line: Remove the plug (24) from the pump

adapter, and install a 1/8 inch diameter weep tube, end-

ing in a waste container. Monitor the weepage of

hydraulic fluid. If it seems excessive or increases sud-

denly, the reciprocatoror pumpthroat seals may need to

be changed. (FIG. 3)

Hydraulic Fluid Control: The hydraulic fluid control pro-

vides pressure regulator, and pump isolation. (FIG. 2)

Pressure Regulation: The hydraulic fluid control reduces

the hydraulic oil pressure to the operating pressure

required for the application.

Flow Regulation: The hydraulic fluid control limits the

maximum amount of oil flow to the motor to keep the

hydraulic motor within the cycle rate limit. This prevents

pump runaway. The limit on the Power-Star is 66 cpm.

Pump Isolation: The hydraulic fluid control has ball

valves on the supply and return sides of the manifold.

The ball valves isolate the hydraulic fluid control and

pump for servicing without stopping the hydraulic power

supply.

Always turn off the hydraulic supply side valve (K)

first to avoid possible serious injury or component

damage. See the Typical Installation on page 6.

FIG. 3

Operation

8308391K

Operation

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever

you see this symbol.

1. Close the supply line shutoff valve, and then the

return line shutoff valve.

2. Open the dispensing valve to relieve the 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

dispense again.

NOTE: If you suspect that the dispensing valve, exten-

sion, or grease fitting coupler is clogged, or that the

pressure has not been fully relieved after following the

steps above, VERY SLOWLY loosen the coupler or

hose end coupling and relieve pressure gradually, then

loosen completely and clear the clog.

Before Starting the Pump

Recommended Hydraulic Oil

Use a 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 motor contact

your Graco distributor. Unauthorized use of lesser grad

oil or substitutes may void the warranty.

1. Check the hydraulic fluid level in the hydraulic power

supply before each use, and add fluid as necessary

to fill the lines.

2. Flush the pump before using it for the first time to

remove the light oil that was left in after factory test-

ing to protect the pump from corrosion. Be sure the

solvent used is compatible with the fluid to be

pumped and the pump’s wetted parts. See Techni-

cal Data, page 18. Flush until clean solvent comes

from the outlet hose.

To Start the Pump

1. Turn on the hydraulic power supply.

2. Open the return line shutoff valve (H) first, and

slowly open the hydraulic supply line shutoff valve

(K). (FIG. 2)

3. Adjust the hydraulic inlet pressure from 500 to 1500

psi (3.5 to 10.3 MPa, 35 to 103 bar) with the regula-

tor control adjustment (M) on the hydraulic fluid con-

trol (A). Increasing the inlet pressure increases the

outlet pressure. Decreasing the inlet pressure

decreases the outlet pressure.

4. 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.

Operation

308391K 9

5. Never allow a pump to run dry of the fluid being

pumped. A dry pump quickly speeds up and can

damage itself. If it speeds up, shut off the power

supply to the reciprocator immediately. Refill the

supply container and prime the pump to eliminate

air.

NOTE: To prevent the pump from running dry, use a

low-level cutoff valve.

Shutdown and Care

At the end of the work shift or when the pump is unat-

tended, always relieve the pressure, see Pressure Relief

Procedure on page 8.

Emergency Stop Procedure

Close the supply line shutoff valve marked STOP.

Troubleshooting

10 308391K

Troubleshooting

1. Follow Pressure Relief Procedure, page 8, before

checking or repairing gun.

2. Check all possible problems and causes before dis-

assembling gun.

Problem Cause Solution

Pump will not run

Closed dispense valve Pump only runs with valve open.

Pressure too low Increase supply pressure using the

pressure adjusting valve.

Insufficient hydraulic fluid supply Check hydraulic power supply.

Adjust to a maximum of 12 gpm

(45.4 lpm) flow

Clogged fluid outlet line, intake

valve, dispense valve, suction line Check; clear obstructions.

Motor stalled Press reciprocator reset button (39).

Pump should start immediately. See

Parts Drawing on page 16.

Reciprocator damaged Repair. See pages 11 through 15.

Pump speeds up or runs erratically

Pump piston and/or intake valve

worn Check and repair. See Page 11

Empty supply container Refill and reprime. Do not allow

pump to run dry. Monitor closely or

use a low-level cutoff valve.

Pump runs, but output low on up

and/or down strokes

Pump piston and/or intake valve

worn Check and repair. See Page 11.

Insufficient material fluid supply Refill fluid supply container.

Pressure too low Increase supply pressure using the

pressure adjustment on the control.

Clogged fluid outlet line, intake

valve, dispense valve, suction line Check; clear obstructions.

Excessive weepage from porous

plug (B) Worn throat seals Repair. See page 11

Hydraulic oil leaks from seal nuts in

the upper housing or cap (36, 43) Seal nuts (19) are loose, worn, or

damaged Tighten the seal nuts. If leaking per-

sists, change the seal nuts.

Pump runs slowly with dispense

valve closed Pump/dispense line leakage If system is OK, rebuild the pump.

Use kits 220457 and 236862.

This manual suits for next models

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