Instructions
Hydraulic Fluid
Controls
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
™
Important Safety Instructions
1500 psi (10.5 MPa, 105 bar) Maximum Working Pres-
sure
3 gpm (11 liters/min) Maximum Flow Rate
Read all warnings and instructions in this
manual. Save these instructions.
Model 236865
Used with Power-Star
™
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.
1500 psi (10.5 MPa, 150 bar) Maximum Working Pres-
sure
12 gpm (45 liters/min) Maximum Flow Rate
Model 236864
Model 236865
Warnings
WARNING
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.
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.
Z V W
Pump: use ground wire and clamp (supplied). Loosen
grounding lug locknut (W) and washer (V). Insert one
2
end of a 12 ga (1.5 mm ) minimum ground wire (Y) into
Y
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.
FIG. 1
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.
4
308395D
Installation
Typical Installation
C
E
C
E
L
L
A
G
J
K
F
G
J
K
F
B
H
H
D
D
Model 236865
Model 236864
FIG. 2: Typical Installation
Key:
A
B
C
D
E
F
G
H
J
Hydraulic Control, 236864
Hydraulic Control, 236865
Hydraulic Return Line
Hydraulic Outlet, 3/4 npsm (A), 1 1/4 npsm(B)
Return Line Shutoff Valve
Hydraulic Inlet, 3/8 npsm (A), 3/4 npsm (B)
Supply Line Shutoff Valve
Pressure Gauge
Pressure Reducing Valve
Flow Control Valve
Hydraulic Supply Line (use only Graco hydraulic power
supply)
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
™
™
K
L
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.
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
5
Installation
Installation Notes
Hydraulic Components
NOTICE
The hydraulic supply system must be kept clean at all
times to reduce the risk of damaging the reciprocator
hydraulic power supply.
• Always turn off the supply side valve (G) to avoid
possible serious injury or component damage.
See the Typical Installation on page 5.
•
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.
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
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
working pressure for Dyna-Star and 1500 psi
™
(10.5 MPa, 105 bar) for the Power-Star .
•
•
•
Do not kink hoses. Adjust swivel connections if nec-
essary.
™
Always use permanently coupled electrically con-
ductive hoses.
Dyna-Star and 10 gpm (37 liter/min) at 1500 psi
™
(10.5 MPa, 105 bar) for the Power-Star .
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.
6
308395D
Operation
Operation
Pressure Relief Procedure
Hydraulic Fluid Level Check
Follow the Pressure Relief Procedure whenever
you see this symbol.
Check the hydraulic fluid level in the hydraulic power
supply before each use, and add fluid as necessary to
fill the lines.
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.
Starting the Pump
•
•
Never exceed 1500 psi (10.5 MPa, 105 bar) Maxi-
mum Hydraulic Pressure to the control.
1. Close the supply line shutoff valve (G), and then
return line shutoff valve (E).
Never exceed 375 psi (2.6 MPa, 26 bar) Maximum
Outlet Pressure from the control when used with a
2. Hold open the dispensing valve to relieve pressure.
™
1/4:1 Dyna-Star pump.
3. Place a container under the drain valve to catch any
drainage. Open the pump outlet drain valve.
•
•
Never exceed 1500 psi (10.5 MPa, 105 bar) Maxi-
mum Outlet Pressure from the control when used
4. Leave the drain valve open until you are ready to
pump again.
™
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,
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.
™
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.
Emergency Stop Procedure
2. Open the return line shutoff valve (E) first and slowly
open the hydraulic supply shutoff valve (G).
Close the red-marked supply line shutoff valve marked
STOP.
3. Remove the cap on the pressure reducing valve to
reveal the cap screw adjustment.
Before Starting the Pump
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.
When starting up the hydraulic system, open the return
line shutoff valve (E) first.
5. Always use the lowest pressure possible to obtain
the desired results. This reduces pump wear.
308395D
7
Repair
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
Flow Control Repair
1. Relieve pressure, see page 7.
2. Remove the flow control valve (K).
There are two basic repairs to the hydraulic fluid control;
pressure control repair and flow control repair.
3. Clean the flow control valve (K) with compatible sol-
vent.
Pressure Control Repair
1. Relieve pressure, see page 7.
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.
2. Remove the pressure reducing valve (J).
3. Clean the pressure reducing valve (J) with a com-
patible solvent.
6. If the control still does not control the flow properly,
replace the valve.
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.
8
308395D
Troubleshooting
Troubleshooting
Problem
Cause
Solution
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
out
Adjust the pressure reducing valve.
Can’t adjust pressure with the pres- Clogged valve
sure reducing valve
Clean the pressure reducing valve.
Insufficient hydraulic power supply
Adjust the hydraulic power supply
pressure. If problem remains refer
to the hydraulic power supply
instruction manual.
pressure
Gauge will not re-zero with the
hydraulic supply and return line
shutoff valves closed
Leak in the supply line shutoff valve Open the return line shutoff valve
(G)
(E) to remove pressure.
Damaged gauge
Replace gauge.
Pump runs away
Contaminated flow control valve
Remove and clean the flow control
valve.
308395D
9
Parts
Parts
110
111
112
102
103
109
105
108
Includes items
113a & 113b
113
104
113b
113a
110
106
103
107
Model 236864 Hydraulic Fluid Control
Ref. Part
111 155494 UNION, swivel, 90°
112 160327 UNION, swivel, 90°
113 189837 MANIFOLD, 3 gpm, includes
replaceable items 113a and 113b
Description
Qty.
Ref. Part
102 108537 VALVE, ball
Description
Qty.
1
1
1
1
2
1
1
1
1
1
1
2
103 112714 HOSE, coupled, 3 ft
104 112567 GAUGE, pressure, fluid
105 112578 VALVE, ball
106 112581 SWIVEL, union, 90°
107 112705 SWIVEL, union, 90°
108 112707 ADAPTER, male
109 112708 ADAPTER, male
110 112715 HOUSE, couple, 3 ft
113a 119902 VALVE, pressure reducing
113b 112712 VALVE, flow regulating, 3 gpm
1
1
10
308395D
Parts
111
105
104
112
110
109
102
108
Includes items
113a & 113b
113
103
113b
113a
107
106
110
111
Model 236865 Hydraulic Fluid Control
Ref. Part
Description
Qty.
Ref. Part
Description
Qty.
111 112716 HOSE, coupled, 3 ft
112 160327 UNION, swivel, 90°
113 189838 MANIFOLD, 12 gpm, includes
items 113a and 113b
113a 119903 VALVE, pressure reducing
113b 112713 VALVE, flow regulating, 12 gpm
2
1
1
102 108537 VALVE, ball
103 112567 GAUGE, pressure, fluid
104 112579 VALVE, ball
105 112580 SWIVEL, union, 90°
106 112705 SWIVEL, union, 90°
107 112706 SWIVEL, union, 90°
108 112708 ADAPTER, male
109 112709 ADAPTER, male
110 112715 HOSE, coupled, 3 ft
1
1
1
1
1
1
1
1
2
1
308395D
11
Technical Data
Technical Data
™
Hydraulic Fluid Controls: Dyna-Star
US
Metric
10.5 MPa, 105 bar
3.5-10.5 MPa, 35-105 bar
11 lpm
Maximum fluid working pressure
Pressure adjusting range
Flow setting
1500 psi
500-1500 psi
3 gpm
Maximum fluid temperature
55°C
130°F
11 lb
Weight
5 kg
Wetted materials
Sound Pressure
Aluminum, steel, nitrile
< 70 dB(A)
See Below
Dimensions
™
Hydraulic Fluid Controls: Power-Star
Maximum fluid working pressure
Pressure adjusting range
Flow setting
1500 psi
10.5 MPa, 105 bar
300-1500 psi
12 gpm
2.0-10.5 MPa, 20-105 bar
45 lpm
55°C
Maximum fluid temperature
130°F
22 lb
Weight
10 kg
Wetted materials
Sound Pressure
Aluminum, steel, nitrile
< 70 dB(A)
See Below
Dimensions
Dimensions
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.
(47.63 mm)
3.75 in.
2.125 in.
(95.25 mm)
4.25 in.
(53.97 mm)
(107.95 mm)
4.25 in.
5.25 in.
(107.95 mm)
(133.35 mm)
Model 236864
Model 236865
12
308395D
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 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 PARTICULAR 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 directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
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.
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.
Revised November 2012
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