Graco Dyna-Star 200:1 User manual

3A7519A
EN
Instructions
Dyna-Star®200:1 and 
120:1 Grease Pumps
For dispensing grease in wellhead valve maintenance and wireline applications only. For
professional use only.
Dyna-Star 200:1
Model No.
25P785: 400 lb Drum Length
25P784: 120 lb. Drum Length
20,000 psi (137.9 MPa, 1379 bar) Maximum Working Pressure

100 psi (0.69 MPa, 6.89 bar) Maximum Air Pressure
Dyna-Star 120:1
Model No.
26A968: 400 lb Drum Length
26A967: 120 lb. Drum Length
12,000 psi (82.7 MPa, 827 bar) Maximum Working Pressure

100 psi (0.69 MPa, 6.89 bar) Maximum Air Pressure
Related Manuals
Important Safety Instructions
Read all warnings and instructions in this
manual before using the equipment. Save
these instructions.
Manual
(English) Description
3A7718 Dyna-Star®Air Motors

Contents
23A7519A
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation Instructions . . . . . . . . . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 8
Before Starting Pump. . . . . . . . . . . . . . . . . . . . . . 8
Priming and Pump Speed Adjustment . . . . . . . . . 9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Suggested tools . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Reassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Recycling and Disposal . . . . . . . . . . . . . . . . . . . . . 18
End of Product Life . . . . . . . . . . . . . . . . . . . . . . 18
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 23
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . 25
Technical Specifications . . . . . . . . . . . . . . . . . . . . 26
California Proposition 65 . . . . . . . . . . . . . . . . . . 27
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 28
Approvals
II 2 G Ex h IIA T4 Gb
NOTE: Type of Protection "h"
applied is constructional safety
"c".

Warnings
3A7519A 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
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.
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.

Warnings
43A7519A
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.
• 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.
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.
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 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.
WARNING

Installation
3A7519A 5
Installation
Typical Installation
Pump Installation on Drum
Key:
A Grounded Air Line
B Air Filter (Graco P/N 106150)
C Air Regulator (required) (Graco P/N 244845)
D Air Line Oiler (Graco P/N 214849)
E Bleed-type Master Air Valve (required)
F Fluid Hose
H Ground Wire (required)
J Follower Plate
K Drum Cover
LAirMotor
M Drain Valve (required)
N Shut-off Valve (required)
P Pressure Gauge (required)
FIG. 1
A
E
B
D
C
K
J
M
N
P
F
L
H

Installation
63A7519A
Installation Instructions
NOTE: The reference letters in the following instructions
refer to Typical Installation, page 5.
Mounting the Pump
• Select a convenient installation location for the
equipment to ensure easy operator access to the
pump air controls, sufficient room to change supply
containers, and a secure mounting platform.
• For mounting the pump directly onto the supply
container, position the pump so that the intake valve
is no more than 1 in. (25 mm) from the bottom of the
container. Mount the pump to the drum cover (K) or
other suitable mounting device.
Pump Accessories
Drain Valve (M): used to relieve fluid pressure in the
pump.
Shut-off Valve (N): used to isolate the pump from
downstream fluid pressure.
Fluid Pressure Gauge (P): monitors the fluid outlet
pressure.
Air Line Accessories
Install the air line accessories (not supplied) as shown in
Typical Installation, page 5.
• Install a bleed-type master air valve (E) (required)
within easy reach of the pump, downstream from the
air regulator (C) (required).
• Install an air filter (B) (optional) to remove harmful
dirt and moisture from the compressed air supply.
For automatic air motor lubrication,
• Install an air line oiler (D) (optional) close to the
pump air inlet.
• Install an air regulator (C) (required) to control the
pump speed.
• Verify that the air hose is properly sized to deliver an
adequate supply of air to the motor. Refer to
Technical Specifications, page 26.
Mount the pump securely so that it cannot move
around during operation. Failure to do so could result
in personal injury or equipment damage.
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 in component ruptures, all
accessories added to the pump fluid outlet side must
have the following maximum working pressures:
• Models 25P784 and 25P785: at least 20,000 psi
(137.9 MPa, 1379 bar) maximum working
pressure.
• Models 26A967 and 26A968: at least 12,000 psi
(82.7 MPa, 827 bar) maximum working pressure.
A bleed-type master air valve (E) is required to shut
off and relieve air pressure that may be trapped in the
air motor (L). Trapped air could cause the pump to
cycle unexpectedly and cause serious bodily injury,
including amputation.

Installation
3A7519A 7
Grounding
Pump: use ground wire and clamp (Graco P/N 222011,
not supplied), as shown in FIG. 2.
1. Connect the ground wire (Y) to the ground screw (Z)
located on the bottom of the air motor.
2. Connect the other end of the ground wire (Y) to a
true earth ground.
Air and fluid hoses: use only electrically conductive
hoses.
Air compressor: follow manufacturer’s
recommendations.
Solvent pails used when flushing: follow local code.
Use only conductive metal pails, placed on a grounded
surface. Do not place the pail on a nonconductive
surface, such as paper or cardboard, which interrupts
grounding continuity.
To maintain grounding continuity when flushing or
relieving pressure: hold metal part of the spray
gun/dispense valve firmly to the side of a grounded
metal pail, then trigger the gun/valve.
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. 2
Y
Z

Operation
83A7519A
Operation
NOTE: The reference letters in the following instructions
refer to Typical Installation, page 5.
Pressure Relief Procedure
1. Close the supply pump’s bleed-type master air valve
(E) (required in the system).
2. Close the shut off valve (N).
3. Open the pump drain valve (M).
4. Check the pressure gauge on the air regulator (C)
and the pressure gauge (P) to verify that pressure
has been relieved.
Before Starting Pump
NOTE: The reference letters in the following instructions
refer to Typical Installation, page 5.
This pump is designed to be used only in pumping
non-corrosive and non-abrasive lubricants. Any other
use of the pump can cause unsafe operating
conditions and component rupture, which can result in
fluid injection or other serious injury or fire or
explosion
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.
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 input pressure.
• Use tubing, hoses, and other components with
pressure ratings equal lo or higher than the pump
rating.
• Do not exceed the maximum output pressure. For
example, the Dyna-Star 200:1 pump has a rated
ratio of 200:1. To calculate the fluid output
pressure, multiply the air pressure shown on the
pressure gauge of the air regulator (C) by 200.
100 psi air x 200 = 20,000 psi fluid output
0.69 MPa air x 200 = 137.9 MPa fluid output
• Do not exceed the maximum pump cycle rate.
• Use the required air regulator (C) to regulate air
pressure to the pump so that no fluid line
component or accessory is over pressurized.

Operation
3A7519A 9
Priming and Pump Speed
Adjustment
NOTE: The reference letters in the following instructions
refer to Typical Installation, page 5.
1. Open the bleed-type master air valve (E).
2. Open the drain valve (M), and slowly open the air
regulator (C) until the pump is running smoothly.
3. After all of the air is purged from the fluid hose,
close the drain valve (M).
4. Use the air regulator (C) to control the pump speed
and fluid pressure. Always use the lowest pressure
necessary to obtain the desired results.
5. The pump will start and stop as the shut-off valve
(N) is opened and closed.
6. If the pump accelerates quickly or is running too
fast, immediately stop the pump by closing the
bleed-type master air valve (E) and check the fluid
supply. If the supply container is empty and air has
been pumped into the lines:
a. Refill the supply container.
b. Prime the pump and fill the lines with fluid to
remove all of the air from the fluid lines.
NOTICE
Never allow the pump to run dry of the fluid being
pumped. A dry pump quickly accelerates to a high
speed and may cause damage to the pump seals.

Maintenance
10 3A7519A
Maintenance
Suggested tools
1/8 in. hex key
3/4 in. socket
15/16 in. socket
15/16 in. open-end wrench
1-7/16 in. socket
1-13/16 in. socket
1-15/16 in. socket
2 in. socket
socket extension
O-ring pick
Torque wrench (50 - 250 ft-lb/ 67.8 - 339 N•m)
Torque wrench (70 in-lb/ 7.9 N•m)
Large adjustable wrenches (1-1/4 in. jaw capacity)
Disassemble
1. Close the bleed type master air valve (E, FIG. 1) to
stall the pump while it is in the down stroke position
(FIG. 3).
2. Relieve pressure following the Pressure Relief
Procedure, page 8.
3. Disconnect the air supply hose from the pump air
motor (1).
4. Disconnect the fluid hose.
5. Remove the pump from the container and place on
a workbench.
6. Remove the muffler (27).
NOTE: Removing the muffler (27) allows easier
movement of the internal pump components to expose
the flats.
7. Remove the four screws (31) holding the mounting
flange (7) using 1/8 in. hex key (FIG. 5).
8. Remove the mounting flange (7), exposing the flats
(FIG. 5).
FIG. 3
FIG. 4
FIG. 5
27
7
31
Flat

Maintenance
3A7519A 11
9. Position the pump horizontally into a vise and
secure on the flats (FIG. 6).
NOTE: Alternative Vice Mounting Orientation: position
pump horizontally into a vice and secure the air motor
(FIG. 7).
10. Using a 1-15/16 in. socket, loosen the inlet pump
cylinder (8) and expose the hex on the connecting
rod (13) (FIG. 8).
11. Using a 3/4 in. socket, loosen and unthread the
shovel rod (20), leaving the shovel rod inside of the
inlet pump cylinder (8) (FIG. 9) and set aside.
12. Using a 1-7/16 in. socket, loosen the seal retainer
(6) but leave it hand-tight in the to the pump cylinder
(2) (FIG. 10).
NOTE: Push the connecting rod in to allow the socket to
reach hex on the seal retainer.
FIG. 6
FIG. 7
Flats
FIG. 8
FIG. 9
13
8
813
20

Maintenance
12 3A7519A
13. Using a 1-13/16 in. socket, remove the pump
cylinder (2) (FIG. 11).
14. Position a wrench on the displacement rod (14) flats
and position another wrench on the fluid piston (9)
flats. Loosen and remove the fluid piston (9) (FIG.
12).
NOTE: The fluid piston (9) can stay connected to the
connecting rod (13).
15. Remove the check ball (15) from inside of the
displacement rod (14) and set aside (FIG. 13).
16. Loosen and remove the three outlet housing
adapter bolts (17) using a 15/16 in. wrench (FIG.
14).
FIG. 10
FIG. 11
6 2
2
FIG. 12
FIG. 13
9
13
14
14
15

Maintenance
3A7519A 13
17. Remove the air motor (1) (FIG. 15).
18. Using a 2 in. socket, loosen and remove the throat
seal retainer nut (19) (FIG. 16).
19. Remove the outlet housing adapter (16) (FIG. 17).
20. Remove the spacer (35), throat seal (5) and the
throat seal back-up rings (4) (FIG. 17).
21. Remove the o-ring face seal (18) (FIG. 17).
Reassemble
1. Replace the o-ring face seal (18) with a new one
from the seal kit (FIG. 18).
2. Replace the backup throat seal (34) with a new one
from the seal kit (FIG. 18),
3. Replace the throat seal (5) and the throat seal
back-up rings (4) with new parts from the seal kit
(FIG. 18).
NOTE: The chamfer on the seal back-up rings must be
pointing away from the seal, the step on the spacer must
be pointing toward the back-up rings. (FIG. 19).
FIG. 14
FIG. 15
FIG. 16
17
1
FIG. 17
FIG. 18
16
5
4
18
19
35
16
5
4
18
34
35

Maintenance
14 3A7519A
4. Reinstall the outlet housing adapter by lining up the
hole in the adapter with the pin on the outlet housing
(FIG. 20).
5. Using a 2 in. socket, reinstall the throat seal retainer
nut (19) and tighten (torque 150 - 165 ft-lb/203.4 -
223.7 N•m) (FIG. 21).
6. Reinstall the air motor (1) by sliding the
displacement rod (14) through the outlet housing (3)
(FIG. 22).
NOTE: Reinstall the air motor in the preferred
orientation for air line connection.
7. Replace and hand-tighten the outlet housing
adapter bolts (17) (FIG. 23).
FIG. 19
FIG. 20
FIG. 21
FIG. 22
FIG. 23
1
3
17

Maintenance
3A7519A 15
8. Replace the check ball (15) between the
displacement rod (14) and the fluid piston (9) (FIG.
24).
9. Remove the piston seal retainer (12), the piston seal
(11), and the piston seal back-up rings (10), and
replace with new parts from the seal repair kit (FIG.
25).
NOTE:
• The chamfer on the seal back-up ring must be
pointing away from the seal (FIG. 26).
• The piston seal has a green o-ring.
10. Reinstall the fluid piston (9) and the connecting rod
(13) using one wrench on the displacement rod flat
and a 15/16 in. socket on the connecting rod (13)
and then tighten (torque 140 - 160 ft-lb/189.8 -
216.9 N•m) (FIG. 27).
11. Remove the seal retainer (6) from the pump cylinder
(2) (FIG. 29).
12. Remove the priming seal (30) and the priming seal
back-up rings (29) and replace with new parts from
the seal repair kit (FIG. 29).
NOTE:
• The chamfer on the seal back-up rings must be
pointing away from the seal (FIG. 28).
• The priming seal has a yellow o-ring.
• Priming seal back-up rings have identification marks
on the chamfered face to distinguish it from the
piston seal back-up rings.
FIG. 24
FIG. 25
FIG. 26
15
11
10
12
FIG. 27
FIG. 28
9
13

Maintenance
16 3A7519A
13. Replace the o-rings (28) on the seal retainer (6)
using the parts from the seal repair kit (FIG. 29).
14. Replace the seal retainer (6) and hand-tighten (FIG.
30).
15. Apply anti-seize lubricant to the male threads of the
pulp cylinder (2) then reinstall the assembly. Tighten
using a 1-13/16 in. socket (torque 235 - 265
ft-lb/318.6 - 359.3 N•m).
16. Using a 1-7/16 in. socket, tighten the seal retainer
(6) to the pump cylinder (2) assembly (torque 100 -
110 ft-lb/135.6 - 149.1 N•m) (FIG. 31).
17. Reinstall the inlet pump tube assembly, connect the
shovel rod (20), located inside of the inlet pump tube
(8), and attach to the connecting rod (13) using a
3/4 in. socket and tighten (torque 55 - 65 ft-lb/ 74.6 -
88.1 N•m) (FIG. 32).
NOTE: The shovel rod (20) should remain inside of the
inlet pump cylinder (8).
18. Reinstall the inlet cylinder (8) and tighten using a 
1-15/16 in. socket (torque 75 - 85 ft-lb/101.7 - 115.2
N•m) (FIG. 33).
NOTE: Remove any grease on the internal threads of
the inlet cylinder before reinstalling to ensure correct
threading.
FIG. 29
FIG. 30
30
29
6
2
28
FIG. 31
FIG. 32
20
8
13

Maintenance
3A7519A 17
19. Reconnect the muffler (27).
20. Attach air supply hose to the pump air motor.
21. Apply air and slowly cycle several times.
22. Remove the air supply hose.
23. Tighten the outlet housing adapter bolts using a
15/16 in. socket (torque 50 - 55 ft-lb/67.8 - 74.6
N•m).
24. Remove the pump from the vise.
25. Replace the mounting plate (FIG. 35).
26. Replace the four screws holding the mounting plate
(7) (torque 60 - 70 in-lb/6.8 - 7.9 N•m) (FIG. 35).
FIG. 33
FIG. 34
FIG. 35

Recycling and Disposal
18 3A7519A
Recycling and Disposal
End of Product Life
At the end of the product’s useful life, dismantle and
recycle it in a responsible manner.
• Perform the Pressure Relief Procedure.
• Drain and dispose of fluids according to applicable
regulations. Refer to the material manufacturer’s
Safety Data Sheet.
• Deliver remaining product to a recycling facility.

Troubleshooting
3A7519A 19
Troubleshooting
1. Follow Pressure Relief Procedure, page 8, before
checking or making repairs repairing to the pump.
2. Check all possible problems and causes before
disassembling the pump.
Problem Cause Solution
Pump fails to operate or there is no
fluid flow.
Inadequate air supply pressure Increase the air supply.
Restricted air line Clear the line.
Closed dispense valves Open the valve.
Clogged fluid lines, hoses, and/or
dispense valve
1. Disconnect the fluid line.
2. Turn the air on. If the pump
starts, the line, hose, and/or
valve is clogged. Clear the
obstruction.
Damaged air motor Service the air motor. See the
Dyna-Star Air Motor manual.
Exhausted fluid supply Refill the fluid supply and prime or
flush.
Continuous air exhaust. Worn or damaged air motor gasket,
packing, seal, etc.
Service the air motor. See the
Dyna-Star Air Motor manual.
Erratic pump operation. Exhausted fluid supply Refill the fluid supply and prime or
flush.
Worn fluid seals Replace worn seals. See Parts,
beginning on page 20.
Inadequate air supply pressure. Increase the air supply.
Pump operates but the output is low
on the down or up stroke.
Worn fluid seals Replace worn seals. See Parts,
beginning on page 20.
Fluid is coming out of the gap
between either the air motor and the
housing adapter or the housing
adapter and the outlet housing.
Worn or damaged throat seal. Replace worn seals. See Parts,
beginning on page 20.

Parts
20 3A7519A
Parts
9
13
8
2
24
17
21
20
18
1
5
4
11
10
19
15
3
31
30 29
28
33
27
12
16
7
22
23
6
34
35