Graco Dyna-Star 24Y408 Use and care manual

3A3429C
Instructions, Repair and Parts
10:1 Dyna-Star®
Pump Module with
Auto-Fill Shutoff
Provides lubricant flow and pressure to operate a single line parallel automatic lubrication
system. For automatic lubrication systems only. For professional use only.
Single Line Parallel Automatic Lubrication
Systems
24Y408: 60 Pound Pump Module
24Y407: 90 Pound Pump Module
25C948: 60# Pump Module with low level sensor
25C949: 90# Pump Module with low level sensor
3500 psi (24 MPa, 240 bar) Maximum Lubricant Outlet
Pressure
3500 psi (24 MPa, 240 bar) Maximum Hydraulic Fluid Inlet
Pressure
5000 psi (34 MPa, 344.7 bar) Maximum Refilling Inlet Pres-
sure
Related Manuals
Important Safety Instructions
Read all warnings and instructions in this manual
and related manuals. Save all instructions.
Manual Description
312350
Dyna-Star Hydraulic Reciprocator and
Pump
309099 Vent Valve Kit
333393 Fill Valve
3A2960 GLC2200 Lubrication Controller
Model 24Y408 Model 24Y407Model 25C949Model 25C948
EN

Table of Contents
23A3429C
Table of Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pump Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Typical Installation (with pressure relief valve). . . 7
Low Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . 8
Typical Installation (with fill valve) . . . . . . . . . . . 10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure Relief Procedure . . . . . . . . . . . . . . . . 12
Pump Module Operation . . . . . . . . . . . . . . . . . . 12
Auto-Fill Shut Off (S) . . . . . . . . . . . . . . . . . . . . . 13
Refilling the Reservoir . . . . . . . . . . . . . . . . . . . . 13
Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Parts Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 24

Warnings
3A3429C 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.
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.
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 Sheet (SDS) 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.

Warnings
43A3429C
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 Safety Data Sheet (SDS) from distributor or retailer.
• 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.
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.
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.
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. 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.

Installation
3A3429C 5
Installation
Read and follow instructions supplied with each system
component.
Grounding
For Mobile Installations
Mount reservoir (K) (FIG. 2, page 7) to a grounded chas-
sis member.
For Non-mobile Installations (FIG. 1)
1. Remove ground screw (gs) and insert through eye
in ring terminal at the end of the ground wire.
2. Fasten ground screw (gs) back into pump and
tighten securely.
3. Connect other end to a true earth ground.
Pump Module
Mount the reservoir (K) on sturdy, flat surface with 6
(six), 3/8-inch diameter bolts. Locate the high pressure
lubricant supply lines (W) and hydraulic lines (T and G)
for easy access once installed.
• The hydraulic system must be depressurized before
connecting high pressure lubricant supply lines (W).
• Be sure breather (J) is not plugged before filling res-
ervoir (K).
• The hydraulic oil supply must be 10µfiltered or better
and supply 0.5 - 3.0 gpm (1.9 - 11.4 lpm) at 300 psi -
3500 psi (21 bar - 241 bar (2.1 MPa - 24 MPa).
1. Install Ball Valve (A) (user provided) in the 3/8-inch
High Pressure Hydraulic Line (G) (FIG. 2, page 7).
2. Connect the 3/4-inch hydraulic tank line (T) (FIG. 2,
page 7) to the tank hydraulic connection swivel (PP)
(FIG. 9, page 11).
3. Connect the 24 VDC timer controlled signal to the
3-way solenoid valve (JJ) (FIG. 9, page 11).
4. Connect high pressure lubricant supply line (W)
(FIG. 2, page 7) to the lubricant output connection
(CC) (FIG. 8, page 11).
5. Ground system (see Grounding).
6. Connect the 3/8-inch high pressure hydraulic line
(G) (FIG. 2, page 7) to the high pressure hydraulic
connection swivel (Y) (FIG. 9, page 11).
Inlet and Outlet Components
LIFTING HAZARD
This equipment is heavy. Lifting or moving heavy
equipment incorrectly can cause serious injury such
as muscle strain or back injuries. To avoid injury:
• Do not lift or move this equipment without assis-
tance.
• Always use a lifting device secured to the pump lift
ring when moving or installing this equipment. See
Technical Data, page 22 for pump weight.
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
gs
COMPONENT RUPTURE HAZARD
The maximum working pressure of the inlet and outlet
components in the system vary. Over-pressurizing an
inlet or outlet can cause it to rupture resulting in prop-
erty damage and serious injury such as skin injection
or injury from splashing fluid. To reduce the risk of
component rupture:
• Be sure to know the maximum working pressure of
each inlet and outlet component in the system.
•Never exceed the maximum working pressure of
the inlet and outlet components.

Installation
63A3429C
Setting the Hydraulic Pressure and Flow
Rate
1. Set the hydraulic pump pressure to the lowest pres-
sure needed using the pressure reducing valve
(NN). This setting should be between 250 - 350 psi
(1.7 to 2.4 MPa, 17.0 to 24.1 bar).
2. Set the hydraulic flow rate to pump at lowest
rate/cycles needed using flow control valve (KK) to
get desired pump speed.
3. With a primed pump and sufficient hydraulic supply,
the pump starts when the timer activates the sole-
noid valve. The pump stops when the timer deacti-
vates the solenoid valve.
Refilling Line (D) Requirements
To relieve the stall pressure in the refilling line (D) a
pressure relief valve (H) (FIG. 2, page 7) or a fill valve
(Z) (FIG. 7, page 10) must be installed in the system.
Systems without Fill Valve
A pressure relief valve (H) and overflow container (N) for
collecting excess fluid that drains during pressure relief,
must be installed in an easily accessible location
between the remote filling station pump (P) and the
Auto-Fill Shut Off (S). This pressure relief valve is used
to relieve pressure in the refilling line (D) and to reset
the Auto-Fill Shut Off. See Typical Installation, page 7.
A Pressure Relief Kit: 247902 is available from Graco.
Contact your distributor or Graco Customer Service for
additional information about this kit.
Systems with Fill Valve (Z)
Install the fill valve (Z) in an easily accessible location
between the remote fill station pump (P) and Auto-Fill
Shut Off Valve (S). See Typical Installation, page 8.
The fill valve is used to relieve pressure in the refilling
line (D) and to reset the Auto-Fill Shut Off (S). See the
fill valve instruction manual 333393. Graco fill valve, part
no. 77X542 is available. Contact your local Graco dis-
tributor.
Refilling Pump (P) Requirements
The remote filling station pump stalls (dead-heads)
when the reservoir is full, causing the supply system
pressure to rise to the maximum output pressure
of the filling station pump. To help prevent equip-
ment damage or serious injury caused by pressur-
ized fluid, such as skin injection or injury from
splashing fluid, always use a remote filling station
pump with a maximum output pressure of 5000 psi
(34 MPa,
344.7 bar) and use a refill line with a pressure rating
equal to or greater than the refill pump.

Installation
3A3429C 7
Typical Installation
Systems with Pressure Relief Valve in the Refilling Line
The installation shown is only a guide for selecting and installing system components. Contact your Graco distributor
for assistance in planning a system to suit your needs.
NOTE: The remote filling station pump stalls (dead-heads) when the reservoir is full. If the pump does not stall
(dead-head) there is a leak in the system.
Key:
A Pump
B Ignition switch
C Refilling Line
D Injector banks
E Lubrication controller
F Pressure Relief Valve*
G Breather
H Reservoir
IVentValve
J Filter (recommended if grease/environment is
contaminated)
K Fluid overflow container*
L Pump - remote filling station
M Reservoir - remote filling station
N Auto-Fill Shut Off
O High-pressure lubricant supply line
P Low level sensor
* A pressure relief valve (F) and overflow container (K) for col-
lecting excess fluid that drains during pressure relief must be
installed in an easily accessible location between the remote
filling station pump (L) and the Auto-Fill Shut Off (N). This
pressure relief valve is used to relieve pressure in the refilling
line and to reset the Auto-Fill Shut Off.
FIG. 2
DO
B
E
M
L
K
H
N
A
F
G
JI
C
P

Installation
83A3429C
Low Level Sensor
When grease is present the LED is green. When the
lubricant level in the reservoir reaches approximately
30% (low level), the LED turns to an amber color. See
FIG. 3 and the table below.
At 30% capacity, the amber low level signals the tank is
reaching a point where the operator should refill the
tank. There is still lubricant in the tank and immediate
shutdown in not required.
If you are using a GLC2200 (part number 24N468,
Series F or later only), the system will enter a low level
warning condition (LL03) after the switch input is closed
for more than 1 second. However, the pump continues
to operate.
FIG. 3
Keep the sensor protective cover (12c on page 17)
installed to prevent sensor damage.
Low level sensor wiring instructions begin below.
Graco GLC2200 (part number 24N468, Series F or later
only) can be used to run the pump and monitor the low
level. Refer to FIG. 5 for Low Level Sensor wiring in sys-
tems controlled with a GLC2200. A Low Level Sensor
cable (part number 129072) and a GLC2200 Wiring
Harness (part number 24P314) are required.
Condition LED Color
Out 2 (Pin #2)
(See Fig. 12, )
Grease present Green 0VDC
No grease present Amber 24 VDC

Installation
3A3429C 9
Low Level Sensor Wiring with GLC2200 Lube Controller
Sensor behaves as a source style sensor
Low Level Sensor Wiring with GLC4400
FIG. 4
Pin Connector
FIG. 5
FIG. 6

Installation
10 3A3429C
Typical Installation
Systems with Fill Valve in the Refilling Line
The installation shown is only a guide for selecting and installing system components. Contact your Graco distributor
for assistance in planning a system to suit your needs.
NOTE: The remote filling station pump stalls (dead-heads) when the reservoir is full. If the pump does not stall
(dead-head) there is a leak in the system.
Key:
D Refilling Line
T Pressure Relief Line
V Instruction Label
Z Fill Valve
Z1 Pressure Relief Knob
NOTE: The components highlighted in FIG. 7 identify the
unique features in a Fill Valve installation. See Typical Installa-
tion on page 7 for a complete list of the other system compo-
nents.
Install the fill valve (Z) in an easily accessible location
between the remote fill station pump (P) and Auto-Fill Shut Off
Valve (S).
The fill valve is used to relieve pressure in the refilling line and
to reset the Auto-Fill Shut Off.
FIG. 7
Z
T
D
Z1
V

Installation
3A3429C 11
Vent Valve Connection
P
Key:
AA Vent Valve hydraulic control line
BB Pump output connection line
CC Lubricant output
DD Pressure relief valve
EE Vent valve
FF Vent line
SS Refilling line
S Auto-Fill Shut Off
Control Module Connection
Key:
GG Pump tank line
HH Pump high pressure hydraulic line
JJ 3-way solenoid valve
KK Flow control valve
LL Vent valve hydraulic control
MM Regulated hydraulic pressure gauge
NN Pressure reducing valve
PP Hydraulic tank connection (swivel)
Y High pressure hydraulic connection (swivel)
*coil should always be installed with lettering facing out
FIG. 8
AA
EE
BB
DD
CC FF
S
SS
FIG. 9
MM
*
LL
NN KK
PP
JJ
HH
GG
Y

Operation
12 3A3429C
Operation
NOTE: Unless otherwise noted, the reference letters
used in the following instructions refer to FIG. 2, page 7.
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Disable hydraulic supply to pump (B) by isolating it
from the high pressure hydraulic supply using ball
valve (A).
2. Do one of the following:
• Cycle the timer [lubrication controller (F)] to
open the 3-way solenoid valve to reduce
trapped hydraulic pressure.
or
• Open pressure reducing valve (NN) to reduce
trapped hydraulic pressure (FIG. 9, page 11).
NOTE: The gauge (MM) on control module should read
zero pressure after performing this step.
3. Disconnect power from lubrication controller (F).
4. Relieve pressure in high pressure supply lines (W)
using two wrenches working in opposite directions
to slowly loosen fitting only until fitting is loose
and no more lubricant or air is leaking from fitting.
Pump Module Operation
Pump Modules for injector-based, Automatic Lubri-
cation Systems: provide lubricant flow and pressure to
operate a single line parallel automatic lubrication sys-
tem. The module requires a hydraulic power supply and
a timed signal from a lubrication controller. Based on
these signals, the pump module provides lubricant flow
and pressure to operate the injectors and vents the
injector system to reset the injectors.
1. Upon receiving a signal from a 24-volt lubrication
controller (F), the 3-way solenoid valve opens, start-
ing the pump (B) and closes the vent valve (L).
2. The pump builds pressure until the pressure switch
in the system sends a signal to the lubrication con-
troller (F) ending the cycle, or the pump (B) stalls.
3. The lubrication controller (F) terminates the 24-volt
signal to the 3-way solenoid valve.
4. The 3-way solenoid valve closes, stopping the
pump (B) and opening the vent valve (L) into the
reservoir (K).
5. The pressure reducing valve (NN) and flow control
valve (KK) control the pump output pressure and
cycle rate (FIG. 9, page 11).
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 Pro-
cedure when you stop dispensing and before clean-
ing, checking, or servicing the equipment.
NOTICE
Never allow pump to run dry of the fluid being
pumped. A dry pump will quickly accelerate to a high
speed, possibly damaging the pump. If your pump
accelerates quickly, or is running too fast, stop the
pump immediately and check the fluid supply.

Operation
3A3429C 13
Auto-Fill Shut Off (S)
The Auto-Fill Shut Off (S) is used for refilling the grease
tank/reservoir in an automatic lubrication system.
NOTE: For systems without a fill valve, see Refilling
Systems without a Fill Valve instructions beginning on
page 13. For systems with a fill valve, see Refilling
Systems with a Fill Valve beginning on page 14.
As grease is added to the reservoir, it pushes the dia-
phragm up to the top of the reservoir. The diaphragm
then pushes the valve pin and closes the inlet fluid path.
When the fluid refilling path closes, the refilling line (D)
pressurizes and brings the refilling pump (P) to a pres-
surized stall condition.
NOTE: The operator must monitor system while filling
tank to reduce the risk of accidental fluid overflow.
Refilling the Reservoir
Refilling Systems without a Fill Valve
1. Connect refilling line (D) from remote filling station
pump (P) to the Auto-fill Shutoff inlet (FIG. 2, page
7).
2. Turn on remote filling station pump (P) and fill reser-
voir (K) until the indicator pin on the Auto-Fill Valve
(S) pushes up as shown in FIG. 10. Pressure in the
refill pump (P) builds and the pump stalls.
3. Turn off air supply to refill pump (P).
4. Relieve pressure between the remote filling station
pump (P) and the Auto-Fill Shut Off (S):
a. Open ball valve (bv) (FIG. 11). Pressure will be
released and excess fluid will drain out of the
drain tube (dt) and into the lubrication collection
container (N).
FIG. 10
pin
up
S
FIG. 11: In line installation shown
bv
G
dt
H

Operation
14 3A3429C
b. Close ball valve (bv) when all pressure has
been relieved.
NOTE: The pin may not drop and the Auto-Fill
Shut Off may not reset because the tank is full.
However, when the pump begins using the
grease, the pin resets. The pin must reset
before the next cycle of refilling.
5. Disconnect lubrication supply hose from the
Auto-Fill Shut Off (S).
6. Install plugs in the Auto-Fill Shut Off inlet and the
refilling line (D) to prevent contaminants from enter-
ing the pump.
Refilling Systems with a Fill Valve (Z)
1. Prior to starting the fill, pull out and hold black pres-
sure relief knob (Z1) long enough to relieve line
pressure between fill valve (Z) (FIG. 13) and
Auto-Fill Shut Off (S).
2. Verify the Auto-Fill Shut Off (S) pin is down, indicat-
ing it is reset (FIG. 14).
3. Remove the yellow dust cover (Z2) from fill coupler
(Z3) (FIG. 13, page 14).
4. Connect the refilling line (D) between the remote fill-
ing stations pump (P) and fill coupler (Z3) port
marked with an “I” (FIG. 13, page 14).
5. Start the remote filling station pump (P).
6. When reservoir (K) is filled:
• the remote filling station pump (P) stalls
(dead-heads),
• the Auto-Fill Shut Off (S) pin pops up (FIG. 15),
• the gauge pressure in the refilling line (D) rises
to the fill pump’s set pressure.
NOTE: If the pump does not stall (dead-head) there is a
leak in the system.
FIG. 12
FIG. 13
pin
drops
Z1
Z2
Z3
Z
FIG. 14
FIG. 15
pin
down
pin
up

Operation
3A3429C 15
7. Relieve pressure between remote filling station
pump (P) and the fill valve (Z):
a. Turn off the remote filling station pump (P).
b. Pull out and hold black pressure relief knob (Z1)
long enough to relieve line pressure between fill
valve (Z) and Auto-Fill Shut Off Valve (S) and
between the remote filling station pump (P) and
fill valve (Z).
NOTE: The length of time it takes to vent varies depend-
ing on the system design and installation. In some
installations it may be necessary to repeat Step b to
ensure pressure is relieved.
c. Disconnect the refilling line (D) at the fill coupler
(Z3).
d. Replace the yellow dust cover (Z2).
Shut Down
(For these instructions, see FIG. 2, page 5).
1. For normal system shut down, disconnect power to
lubricator controller (F) by turning off the ignition
switch.
2. Turn of hydraulic supply by closing ball valve (A).

Service
16 3A3429C
Service
Use only Genuine Graco Repair Parts.
See separate system component manuals for service
instructions. For pump service see manual 312350. For
vent valve service see manual 309099.
Troubleshooting
Problem Cause Solution
System does not build sufficient pres-
sure.
Pump (B) malfunction. Refer to manual 312350.
Pump (B) turned off too soon. Increase lubrication controller (F)
“pump on” setting.
Increase hydraulic flow rate to pump
(F).
Solenoid (JJ) malfunction. Repair or replace solenoid (JJ).
Too low or no hydraulic supply. Turn pressure up or supply on.
Vent valve (L) seal failure. Replace seal.
Vent valve (L) needle/seat failure. Replace needle and seat.
Reservoir (K) out of grease. Fill reservoir (K).
Broken or leaky supply/branch line. Tighten connections and/or replace
line(s).
Injector failure. Repair or replace injector.
Pressure in tank line too high due to
restrictions in tank line or plumbing
too small.
Remove tank line restrictions.
Use larger plumbing.
Lubricant dispensed from pressure
relief valve.
System pressure set too high. Decrease hydraulic pressure to
pump.
Pump (B) runs too fast. Reservoir (K) out of lubricant. Fill reservoir (K).
Leak in distribution system. Repair leak.
Lubricant coming out of breather (J). Reservoir (K) overfilled because
Auto-Fill Shut Off (S) did not shut the
refilling line (D).
Replace the Auto-Fill Shut Off (S)
diaphragm (9) and Auto-Fill Shut Off
valve (8).

Troubleshooting
3A3429C 17
Pump (B) will not start. No hydraulic supply. Verify/check hydraulic supply.
Solenoid (JJ) malfunction. Replace solenoid (JJ).
No electrical supply to lubrication
controller (F).
Turn on electrical supply.
Lubrication controller (F) malfunction. Refer to lubrication controller man-
ual.
Pump (B) malfunction. Refer to pump manual 312350.
Refilling pump (P) slows down or
stalls and no output at the fill valve
(Z).
Auto-Fill Shut Off Valve (S) has not
reset
Relieve all refilling line (D) pressure.
see page 13.
Make sure Auto-Fill Shut Off (S) pin
is down. See FIG. 14, page 14.
Refilling pump (P) runs continuously
but does not stall.
Leakage in the system Inspect the refilling line (D) and cor-
rect any leaks.
Problem Cause Solution

Parts Drawing
18 3A3429C
Parts Drawing
(See Parts List, page 20)
Pump hydraulic outlet
Pump hydraulic inlet
13j
3l
3k
3i
3d
3a
3g
3c
3f
3h
3e
7
3b
8
5, 6
2
2m
3a
3l
4
9
10
11 2m
12c
12b
12a

Parts Drawing
3A3429C 19
Parts Drawing
Vent Valve Kit (2): 243170
Control Module Kit (4): 247538
To pump hydraulic inlet
To pump
To pump
lubricant outlet
4m
4q
4u
4t
4c*
4d*
4e*
4a*
4n
4j
4b
4h*
4f*
4g*
4r
4n
4k
2h
2n
2g
2b
2p
2e
2c
2i
2d
2a
2f
2m
3a
3b
2q
4a*/4h* Torque 40-43 ft-lbs (54-58 Nm)
4c*/4e* Torque 15-20 ft-lbs (20-27 Nm)
4d* Torque 20-25 ft-lbs (27-34 Nm)
4f* Torque 68-75 ft-lbs (92-102 Nm)
4g* Torque 22-24 ft-lbs (30-33 Nm)
4s* Allows user to plug vent line for use in systems without a vent valve
* Lubricate o-ring with oil before installation
hydraulic outlet
4s*

Parts List
Model 24Y408: Dyna-Star 10:1 Pump Module, 60# for Single Line, Parallel, Automatic Lubrication Systems
Model 24Y407: Dyna-Star 10:1 Pump Module, 90# for Single Line, Parallel, Automatic Lubrication Systems
Ref.
No. Part No. Description Qty
1
247540 PUMP, Dyna-Star 60#,
see manual 312350 1
247443 PUMP, Dyna-Star 120#, see
manual 312350
2 243170 KIT, installation, vent valve 1
2a 100505 . BUSHING, pipe 1
2b 100840 . ELBOW, street 1
2c 100896 . FITTING, bushing, pipe 1
2d . SCREW, cap, hex hd 2
2e 115122 . VALVE, pressure relief 1
2f 161889 . UNION, adapter 1
2g 157705 . UNION, swivel 1
2h 158212 . BUSHING 1
2i 155470 . UNION, union, swivel, 90 degree 1
2m 194995 . HOSE, vent; 1/2 in. 2
2n 238370 . HOSE 2
2p 242063 . VALVE, vent 1
2q 156684 . UNION, adapter 1
3
25C948 Pump Module, 60#, AFSO, LL,
grease 1
25C949 Pump Module, 90#, AFSO, LL,
grease 1
3a 100737 . PLUG, pipe 2
3b 108126 . TEE, pipe 1
3c . NUT, flanged, hex 6
3d . SCREW, cap, flange head 4
3e 115254 . BREATHER 1
3f 194868 . GASKET, cover 1
3g
15R105 . PAIL, reservoir, 60#,
models 24Y408 1
194907 . PAIL, reservoir, 90#,
models 24Y407 1
3h 16X912 . COVER, reservoir 1
3i 104663 . PLUG, pipe 1