Graco 312350E Use and care manual

312350E
Instructions, Repair and Parts
Dyna-Star®
HYDRAULIC RECIPROCATOR AND PUMP
- For lubricating fluids only -
10:1 Ratio Universal Pump and Reciprocator
600 psi (4.1 MPa, 41 bar) Maximum Hydraulic Input Pressure
7500 psi (51 MPa, 517 bar) Maximum Fluid Outlet Pressure
Model 247540: Pump, 60 lb Automatic Lube Pump Module Length
Model 247443: Pump, 120 lb Drum Length
Model 247450: Pump, 400 lb Drum Length
Table of Contents
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Warnings 2
Installation 4
Operation 7
Troubleshooting 9
Service 10
Reciprocator Parts 18
Pump Parts 20
Technical Data 21
Graco Standard Warranty 23
Graco Information 23
ti10604a
Model 247443 Shown

Warnings
2312350E
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 symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found 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.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
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 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 forms from distributor or retailer.
• 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.
• 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.
SKIN INJECTION HAZARD
High-pressure fluid from dispense valve, 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 dispense valve at anyone or at any part of the body.
• Do not put your hand over the end of the dispense nozzle.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.

Warnings
312350E 3
MOVING PARTS HAZARD
Moving parts can pinch 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 in this manual. Disconnect power or air supply.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
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 MSDS’s 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 impervious gloves when spraying or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection
WARNING

Installation
4312350E
Installation
Key:
A Follower plate
B Weep tube
C Fluid outlet line (to gun)
D Drain valve (required)
E Ground wire
F Hydraulic return line, minimum 3/4 inch I.D. (required)
G Hydraulic outlet, 3/4” npt (f)
H Return line shut-off valve, minimum 3/4 inch (required)
J Hydraulic inlet, 3/4” npt (m)
K Tee, 3/4” npt
L Supply line shut-off valve (required)
M *Pressure gauge
N *Pressure reducing valve (required in systems over 600
psi [4.1 MPa, 41 bar])
P Accumulator
Q *Flow control valve (required in systems over 3 gpm [11
lpm])
R Hydraulic supply line
SCheckvalve
T Variable volume pressure compensated pump
U Hydraulic power supply
V Drain line, accumulator
*Included in Hydraulic Fluid Control Kit 247538 or 247705, which can be ordered separately.
FIG. 1
Although the installation shown in FIG. 1 is only a guide
for selecting and installing system components and
accessories, some of the equipment is required, as
noted in the key. For assistance in designing a system to
suit your needs, contact your Graco distributor.
Mount pump to suit the type of installation planned.
ti0477a
Typical Installation of a
Suction Feed System
U
T
S
R
Q
P
N
M
L
K
J
H
G
F
D
C
B
A
E
CAUTION
Do not operate pump without it being securely
mounted to a drum cover or support.
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 component ruptures, all
accessories added to the reciprocator power supply
side must have at least 600 psi (4.1 MPa, 41 bar)
maximum working pressure.
All accessories added to the pump fluid outlet side
must have at least 7500 psi (51 MPa, 517 bar)
maximum working pressure.

Installation
312350E 5
Pump Accessories
Follower Plate (A): ensures a good prime. Place
follower plate on grease and rotate while pressing firmly
to level material. Order part number 247700 for 60# and
90# automatic lube pump modules; 247701 for 120#
refinery reservoir; or 247702 for 400# refinery reservoir.
Pump Outlet Drain Valve (D): helps relieve fluid
pressure in pump when pump is shut off. Install valve
close to pump fluid outlet. Order valve, Part No. 111229.
Hydraulic Power Supply
See FIG. 1.
The hydraulic power supply system (U) must have a
pressure reducing valve and a pressure-compensated
flow control. A flow control valve (Q) is required to limit
the incoming flow to the reciprocator to a maximum of 3
gpm (11 lpm).
Hydraulic Lines
Shut-off Valves (H, L): installed on the hydraulic supply
and return lines. Order Part No. 108537 and 112578.
Drain Line: Monitor the weepage of hydraulic fluid or
lubricant. If it seems excessive or increases suddenly,
the reciprocator/pump seals may need to be changed.
See FIG. 2.
FIG. 2
Hoses: Use a minimum 1/2 inch supply line (R) and
minimum 3/4 inch return line (F) on the reciprocator.
Contact your Graco representative for details of line
sizing.
Pressure Reducing Valve (N): circulates excess
hydraulic fluid pressure back to the hydraulic power
supply. Install this valve (N) in the hydraulic supply line
with a drain hose (W) teed into the hydraulic return line
(F). Limit supply pressure to a maximum 600 psi (4.1
MPa, 41 bar).
Accumulator (P): reduces hammering effect caused by
the motor when it reverses direction.
Fluid-filled Pressure Gauge (M), Part No. 112567:
monitors hydraulic pressure to the reciprocator during
startup. See FIG. 1. Use the gauge for initial adjustment
of the reciprocator. It can be removed after adjustment.
Pump Outlet Drain Valve
• A pump outlet drain (D) is required in your system.
This valve helps relieve pressure in the displace-
ment pump and hose when shutting down system
and in case of a clogged outlet hose. Install valve
close to pump outlet.
• Mount pump securely so it cannot move around
during operation. Failure to do so could result in
personal injury and/or equipment damage.
Limit Fluid Flow to Reciprocator
To reduce the risk of overpressurizing the hydraulic
reciprocator which could cause a rupture and serious
injury, including fluid injection, a hydraulic system
must have a means to limit the incoming fluid flow to
the reciprocator to a maximum of 3 gpm (11 lpm) and
600 psi (4.1 MPa, 41 bar). See description below.
Pressure gauge (M), pressure reducing valve (N)
and a flow control valve (Q) are included in the
Hydraulic Fluid Control Kit 247538 or 247705,
which can be ordered separately.
ti10602a

Installation
6312350E
Grounding
To reduce the risk of static sparking, ground pump.
Check your local electrical code for detailed grounding
instructions for your area and type of equipment.
•Pump: Use ground wire and clamp as shown in
FIG. 3. Order Grounding Wire and Clamp Kit,
Part No. 222011.
•Hydraulic Hoses and Fluid Outlet Hoses:
Use electrically conductive hoses only.
•Hydraulic Power Supply: Follow manufac-
turer’s recommendations.
•Flushing Pails: When flushing, only use metal,
grounded pails. Make firm, metal-to-metal con-
tact between the metal part of the dispense
valve and the pail. Use lowest possible pres-
sure.
Grounding the Pump
To ground pump (See FIG. 3):
1. Remove ground screw (Z) and insert through eye of
ring terminal at end of ground wire.
2. Fasten ground screw back onto pump and tighten
securely.
3. Connect other end of wire to a true earth ground.
FIG. 3
Z
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Operation
312350E 7
Operation
Pressure Relief Procedure
The system pressure must be manually relieved to
prevent the system from starting or dispensing
accidentally. Follow this pressure relief procedure
whenever you are instructed to:
• relieve pressure.
• check or service any system equipment.
• install or clean nozzle.
For the following instructions, see FIG. 1.
1. Shut off hydraulic power supply.
2. Close supply line shut-off valve (L).
3. Open dispensing valve to relieve pressure.
4. Open pump outlet drain valve. Have a container
ready to catch drainage.
5. Close return line shut-off valve (H).
If you suspect the nozzle or hose is completely clogged
or that pressure has not been fully relieved after
following steps 1-5 above, very slowly loosen the hose
end coupling to relieve pressure, then clear obstruction.
Before Starting Pump
• Check hydraulic fluid level in hydraulic power supply
before each use. Add fluid as necessary to fill the
lines.
• Flush pump before using it for the first time to
remove the light oil that was left in after factory test-
ing to protect pump from corrosion. Be sure 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 out of hose.
Leave drain valve open until you are ready to
dispense again.
COMPONENT RUPTURE HAZARD
Overpressurizing any component can result in
serious injury or property damage as a result of
rupture, fire, and/or explosion.The maximum working
pressure of each component in the system may not
be the same. To reduce the risk of overpressurizing
any component in the system:
• Be sure you know the maximum working
pressure of each component.
•Never exceed the maximum working pressure of
the lowest rated component in the system.
• Do not exceed the maximum pump cycle rate.
• The pump has a rated ratio of 10:1. However, it is
capable of reaching stall pressures equal to 12.5
times the hydraulic input pressure. To calculate
the fluid output pressure, multiply the hydraulic
pressure shown on the hydraulic control module
gauge by 12.5.
For example:
600 psi hydraulic x 12.5 = 7500 psi fluid output
4.14 MPa hydraulic x 12.5 = 51.8 MPa fluid
output
41.4 bar hydraulic x 12.5 = 5.18 bar fluid output
• Regulate hydraulic pressure to the pump so that
no fluid line component or accessory is
overpressurized.

Operation
8312350E
Starting Pump
1. Turn on hydraulic power supply.
2. Open return line shut-off valve (H) first, then slowly
open the hydraulic supply shut-off valve (L).
3. Adjust flow control valve (Q) to limit the hydraulic
flow to no more than 3 gpm (11 lpm), which is
approximately 60 cycles per minute.
4. Adjust pressure reducing valve (N) to increase
hydraulic inlet pressure from 50 to 600 psi (0.34 to
4.1 MPa, 3.4 to 41 bar).
• Increasing inlet pressure, increases outlet pres-
sure.
• Decreasing inlet pressure, decreases outlet
pressure.
5. Open drain valve while priming pump.
6. When pump is primed, close drain valve.
Always use lowest pressure possible to obtain desired
results. This reduces pump wear.
If the Pump Leaks at the Fluid
Fittings
Tighten fittings (1, 5, 60) which are self-sealing and
have replaceable o-rings. If leaking persists, change
o-rings.
FIG. 4
Shutdown
Relieve pressure, page 7, whenever you shutdown.
Maximum Working Pressures
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:
• Never exceed 600 psi (4.1 MPa, 41 bar) Maxi-
mum Hydraulic Pressure to the reciprocator.
• Never exceed 7500 psi (51 MPa, 517 bar) Maxi-
mum Outlet Pressure from the displacement
pump.
• Accessories added to the pump fluid outlet side
should have at least a 7500 psi (51 MPa, 517
bar) Maximum Working Pressure.
• Read and understand COMPONENT RUP-
TURE HAZARD instructions, page 7.
sealing
fitting (1, 5, 60)
reciprocator
o-ring
(1a, 5a,60a)
ti04478

Troubleshooting
312350E 9
Troubleshooting
Problem Cause Solution
Pump does not run. Closed dispense valve. Pump only runs with valve open.
Pressure too low. Increase supply pressure using a
pressure adjusting valve.
Insufficient hydraulic fluid supply. Check hydraulic supply. Adjust to a
maximum of 3 gpm (11 lpm) flow.
Clogged fluid outlet line, intake valve,
dispense valve, suction line.
Relieve pressure, page 7. Check.
Clear obstructions.
Reciprocator damaged. Repair.
Pump speeds up or runs erratically. Pump piston and/or intake valve
worn.
Relieve pressure, page 7. Check
and repair.
Empty supply container. Refill and repair. 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 stroke.
Pump piston and/or intake valve
worn.
Relieve pressure, page 7. Check
and repair.
Pump run but output low on both up
and down strokes.
Insufficient hydraulic fluid supply. Check hydraulic supply. Adjust to
maximum 3 gpm (11 lpm) flow.
Pressure too low. Increase supply pressure using a
pressure adjusting valve.
Clogged fluid outlet line, intake valve,
dispense valve, suction line.
Relieve pressure, page 7. Check.
Clear obstructions.
Excessive weepage from weep tube
(B), page 4.
Worn throat packings. Repair.
Worn displacement seal. Repair.
Hydraulic oil leaks from fittings in the
upper or lower reciprocator blocks
(31, 32) [Parts page 18].
Fittings 1, 5, 58, (Parts, page 18), are
loose, or their o-rings are worn or
damaged.
Tighten the self-sealing fittings. If
leaking persists, change o-rings.

Service
10 312350E
Service
Replacing Throat Seals
See FIG. 5.
1. Relieve pressure, page 7.
2. Disconnect reciprocator from pump.
3. Remove four capscrews (15) from bottom of adapter
(43). Tap adapter to loosen it and pull it off the bot-
tom cap (32).
4. Remove seal (44, included in Reciprocator Repair
Kit 247455) from top of adapter (43).
5. Install seal (16) in adapter (43) in the order shown in
FIG. 5.
6. Reassemble. Torque the capscrews (15) to 28-32
ft-lb (38 to 43 N.m). Install displacement pump, see
Step 23 on page 15.
FIG. 5
Use of a hydraulic power supply with fluid tempera-
tures above 154°F (68°C) can create hot surfaces
which can burn if touched.
• Do not touch pump, motor, or if hydraulic system
fluid is above 154°F (68°C).
• Allow sufficient time for pump and motor to cool
before attempting any service or repair.
Replace throat seals if fluid leaks excessively
through the weep tube (B), page 4. This procedure
can be done without disassembling entire
reciprocator.
32
44
8
3
35
15
19
11
Torque to 170 - 180 in-lbs (19-20 N.m)
4
ti10463a
1
1Lips face down.
Torque to 54-56 ft-lbs (73-76 N.m).
3
4
27
10