Graco Power-Star 236754 User manual

Instructions - Parts List
Power-Star™308391K
EN
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
Y
Z

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
H
R
E
N
A
G
J
L
M
B
P
D
C
K
F
S
T

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
24

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.