Graco Power-Star B Series Bedienungsanleitung

Instructions - Parts List

Power-Star™308391P

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

Model No. 236754, Series B

1:1 Ratio Universal Pump and Reciprocator

Model No. 236752, Series B (Square Housings), Series C (Cylindrical Housings)

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 before using the equipment.

Save these instructions.

WARNING

This pump is designed to be used only in pumping

non-corrosive and non-abrasive oils and lubricants. Any

other use of the pump can cause unsafe operating

conditions and result in component rupture, fire, or

explosion, which can cause serious injury, including fluid

injection.

Model 236752,

Series B

Model 236752,

Series C Model 236754,

Series B

2 308391P

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

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Model 236752, Series B - Square Housings . . . 15

Model 236752, Series C - Cylindrical Housings. 17

Model 236754, Series B - Cylindrical Housings. 19

Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Performance Chart . . . . . . . . . . . . . . . . . . . . . . . . . 21

California Proposition 65 . . . . . . . . . . . . . . . . . . . . 21

Graco Standard Warranty. . . . . . . . . . . . . . . . . . . . 22

IMPORTANT

The design of the Viscount II hydraulic pump upper and lower motor housings has been updated. This cylindrical

design replaces the square housing design previously used. There is no performance change associated with this

update.

If replacement of a square housing is necessary, both upper and lower housings should be converted to the

cylindrical design as it is not backwards compatible.

Unless otherwise specified in this manual, all Instructions apply to both Square and Cylindrical Series of Models.

Warnings

308391P 3

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The

exclamation 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.

•Ground all equipment in the work area.

•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.

•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

4 308391P

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

component. See Technical Specifications in all equipment manuals.

•Use fluids and solvents that are compatible with equipment wetted parts. See Technical

Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For

complete information about your material, request Safety Data Sheets (SDSs) 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

manufacturer’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 Safety Data Sheets (SDSs) 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.

BURN HAZARD

Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe

burns:

•Do not touch hot fluid or 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.

•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

308391P 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.

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

ground. (FIG. 1)

Hydraulic and fluid hoses: Use only electrically

conductive hoses.

Hydraulic power supply: Follow manufacturer’s

recommendations.

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.

The equipment must be grounded to reduce the risk

of static sparking. Static sparking can cause fumes

to ignite or explode. Grounding provides an escape

wire for the electric current.

FIG. 1

Installation

6 308391P

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)

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

supply, 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

Note: Square housings shown

Installation

308391P 7

Hydraulic Components

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

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

ending in a waste container. Monitor the weepage of

hydraulic fluid. If it seems excessive or increases

suddenly, the reciprocator or pump throat seals may

need to be changed. (FIG. 3)

Hydraulic Fluid Control: The hydraulic fluid control

provides pressure regulator, and pump isolation. (FIG.

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

8 308391P

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.

If you suspect that the dispensing valve, extension, 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

grade 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

testing 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

Technical Data, page 20. 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

regulator control adjustment (M) on the hydraulic

fluid control (A).

Increasing the inlet pressure increases the outlet

pressure. Decreasing the inlet pressure decreases

the outlet pressure. Always use the lowest pressure

possible to obtain the desired results. This reduces

pump wear.

To prevent the pump from running dry, use a low-level

cutoff valve.

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.

NOTICE

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.

Operation

308391P 9

Shutdown and Care

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

unattended, always relieve the pressure, see Pressure

Relief Procedure on page 8.

Emergency Stop Procedure

Close the supply line shutoff valve marked STOP.

Troubleshooting

10 308391P

Troubleshooting

1. Follow Pressure Relief Procedure, page 8, before

checking or repairing gun.

2. Check all possible problems and causes before

disassembling 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 15.

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

persists, 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.

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