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