Graco Dyna-Star 224912 User manual

Instructions – Parts List
308156M
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 23 for maximum working pressures.
PROVEN QUALITY, LEADING TECHNOLOGY
Dyna–Start
HYDRAULIC RECIPROCATOR AND PUMP
1500 psi (10 MPa, 102 bar) Maximum Hydraulic Input Pressure
7500 psi (51 MPa, 517 bar) Maximum Fluid Outlet Pressure
FOR LUBRICATING FLUIDS ONLY
5:1 Ratio Universal Pump and Reciprocator
Model 224912, Series C, 35 lb. pail size
Model 224751, Series C, 120 lb. drum size
Model 224752, Series C, 400 lb. drum size
Model 239883, Series A, reciprocator only
06151B
Patent No. 4,383,475
Foreign Patents Pending
Patent 1984 Canada
Brevete 1984

2 308156
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing Throat Seals 11. . . . . . . . . . . . . . . . . . . . . .
Disconnecting the Reciprocator
and Displacement Pump 12. . . . . . . . . . . . . . . . . . . . .
Reciprocator Repair 13. . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Repair 17. . . . . . . . . . . . . . . . . . .
Parts 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 19. . . . . . . . . . . . . . . . . . . . . . . . .
Reciprocator 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Parts 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions and Mounting Hole Layout 23. . . . . . . . . . .
Graco Standard Warranty 24. . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 24. . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the corresponding
instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
corresponding instructions.
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure of the lowest rated component in your system.
This equipment has a 1500 psi (10 MPa, 102 bar) maximum hydraulic input pressure and
7500 psi (51 MPa, 517 bar) maximum fluid outlet pressure.
DUse fluids and solvents that are compatible with the equipment wetted parts. Refer to the Techni-
cal Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
DHandle hoses carefully. Do not pull on hoses to move equipment.
DRoute hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not ex-
pose Graco hoses to temperatures above 82_C (180_F) or below –40_C (–40_F).
DDo not lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.
WARNING
WARNING

308156 3
TOXIC FLUID HAZARD
Hazardous fluids or toxic fumes can cause serious injury or death if splashed in the eyes or on the
skin, inhaled, or swallowed.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer.
SKIN INJECTION HAZARD
Fluid from the dispensing valve, leaks or ruptured components can inject fluid into your body and
cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on
the skin can also cause serious injury.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate sur-
gical treatment.
DDo not point the dispensing valve at anyone or at any part of the body.
DDo not put your hand or fingers over the end of the dispensing valve.
DDo not stop or deflect leaks with your hand, body, glove or rag.
DUse only extensions and couplers that are designed for use with your dispensing valve.
DDo not use a low pressure flexible nozzle with this equipment.
DFollow the Pressure Relief Procedure on page 8 if the grease fitting coupler clogs and before
cleaning, checking or servicing the equipment.
DTighten all fluid connections before operating the equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do
not repair high pressure couplings; you must replace the entire hose.
DFluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
WARNING
WARNING

4 308156
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
DKeep clear of all moving parts when starting or operating the pump.
DBefore servicing the equipment, follow the Pressure Relief Procedure on page 8 to prevent the
equipment from starting unexpectedly.
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames, or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
DGround the equipment and the object being dispensed to. Refer to Grounding on page 7.
DIf there is any static sparking or you feel an electric shock while using this equipment, stop
dispensing immediately. Do not use the equipment until you identify and correct the problem.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being dispensed.
DKeep the dispense area free of debris, including solvent, rags, and gasoline.
DDo not smoke in the dispense area.
DDo not turn on or off any light switch in the dispense area while dispensing or while operating if
fumes are present.
WARNING
WARNING

308156 5
Installation
Fig. 1
KEY
AFollower plate
BWeep tube
CFluid outlet line (to gun)
DDrain valve (required)
EGround wire
FHydraulic return line, minimum
3/4” I.D. (required)
GHydraulic outlet, 1/2 npt
HReturn line shut-off valve,
minimum 3/4” (required)
JHydraulic inlet, 1/2 npt
KTee, 3/4 npt
L* Supply line shut-off valve
M* Pressure gauge
N* Pressure reducing valve
(required in systems over 1500 psi
[10 MPa, 102 bar])
PAccumulator
Q* Flow control valve
(required in systems over 3 gpm
[11 lpm])
RHydraulic supply line
SCheck valve
TVariable volume pressure
compensated pump
UHydraulic power supply
WDrain line, accumulator
Typical Installation of a
Suction Feed System
AB
C
DE
FGHJKLMN
P
Q
R
STU
W
04477A
*Included in Hydraulic Fluid Control Kit 236864, which can be ordered separately.
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 the pump to suit the type of installation planned.
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 sup-
ply side must have at least a 1500 psi (10 MPa,
102 bar) maximum working pressure.
All accessories added to the pump fluid outlet side
must have at least a 7500 psi (51 MPa, 517 bar)
maximum working pressure.
WARNING
Pump Accessories
DFollower plate (A) ensures a good prime.
Place the plate on the grease and rotate while
pressing firmly to level the material.
DPump outlet drain valve (D) helps relieve
fluid pressure in the pump when the pump is
shut off. Install the valve close to the pump
fluid outlet. Order Part No. 111229, valve.
WARNING
Pump Outlet Drain Valve
A pump outlet drain valve (D) is required in your
system. This valve helps relieve pressure in the
displacement pump and hose when shutting down
the system and in case of a clogged outlet hose.
Install the valve close to the pump outlet.

6 308156
Installation
WARNING
Mount the pump securely so that it cannot move
around during operation. Failure to do so could
result in personal injury or equipment damage.
NOTE: Refer to Fig. 1 to locate the parts mentioned
below.
Keep the Hydraulic System Clean
The hydraulic supply system must be kept clean at
all times to reduce the risk of damaging the recip-
rocator hydraulic power supply. Blow out all hy-
draulic lines with air, flush thoroughly with solvent,
and then blow out with air again before connecting
the lines to the reciprocator.
Always plug the hydraulic inlets, outlets and lines
when disconnecting them for any reason to avoid
introducing dirt and other contaminants into the
system.
Carefully follow the manufacturer’s recommenda-
tions on reservoir and filter cleaning, and periodic
changes of hydraulic fluid.
CAUTION
Hydraulic Power Supply
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, the hydraulic
system must have a means to limit the incoming
fluid flow to the reciprocator to a maximum of 3
gpm (11 lpm) and 1500 psi (10 MPa, 102 bar). See
the description below.
WARNING
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).
NOTE: A supply line shut-off valve (L), pressure gauge
(M), pressure reducing valve (N), and a flow control
valve (Q) are included in the Hydraulic Fluid Control Kit
236864, which can be ordered separately.
Hydraulic Lines
DShut-off valves (H and L) are installed in the
hydraulic supply and return lines. Order Part
No. 108537.
DDrain Line: Remove the plug (59) from the
pump adapter and install a 1/8” diameter weep
tube (B), ending in a waste container. Monitor
the weepage of hydraulic fluid. If it seems
excessive or increases suddenly, the
reciprocator/pump seals may need to be
changed. See Fig. 2.
Fig. 2
59
06146B
DHoses: Use a minimum 1/2” supply line (R)
and minimum 3/4” return line (F) on the
reciprocator. Contact your Graco
representative for details of line sizing.
DA 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 of 1500 psi
(10 MPa, 102 bar).
DAn accumulator (P) reduces the hammering
effect caused by the motor when it reverses
direction.
DA 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 is made.

308156 7
Installation
Grounding
To reduce the risk of static sparking, ground the pump.
Check your local electrical code for detailed grounding
instructions for your area and type of equipment.
DPump: Use ground wire and clamp as shown in Fig.
3. To order a Grounding Wire and Clamp Kit, order
Part No. 222011.
DHydraulic Hoses and Fluid Outlet Hoses: Use only
electrically conductive hoses.
DHydraulic Power Supply: Follow manufacturer’s
recommendations.
DAny pails used when flushing: Use only metal,
grounded pails when flushing. Make firm metal to
metal contact between the a metal part of the
dispense valve and the pail. Use the lowest
possible pressure.
To ground the pump, remove the ground screw (Z)
and insert through the eye of the ring terminal at end of
ground wire (Y). Fasten the ground screw back onto
the pump and tighten securely. Connect the other end
of the wire to a true earth ground.
Fig. 3
Y
Z
06147B

8 308156
Operation
Pressure Relief Procedure
SKIN INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or dispensing accidentally. Fluid
under high pressure can be injected through the
skin and cause serious injury. To reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you
DAre instructed to relieve the pressure
DCheck or service any of the system equipment
DInstall or clean the nozzle
WARNING
1. Shut off the hydraulic power supply.
2. Close the supply line shut-off valve (L in Fig. 1).
3. Open the dispensing valve to relieve pressure.
4. Open the pump outlet drain valve, and have a
container ready to catch the drainage.
5. Close the return line shut-off valve (H).
NOTE: Leave the drain valve open until you are ready
to dispense again.
If you suspect that the 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 to relieve pressure, then clear the
obstruction.
Before You Start the Pump
1. Check the hydraulic fluid level in the hydraulic
power supply before each use,and add fluid as
necessary to fill the lines.
CAUTION
Always use Graco approved hydraulic oil or equiv-
alent, Part Numbers 169236 (5 gallon) or 207428
(1 gallon). Do not substitute lower grade oil.
2. Flush the pump before using it for the first time to
remove the light oil that was left in after factory
testing to protect the pump from corrosion. Be sure
the solvent used is compatible with the fluid to be
pumped and the pump wetted parts. See
Technical Data, page 23. Flush until clean solvent
comes from the outlet hose.
To start the pump
1. Turn on the hydraulic power supply.
2. Open the return line shut-off valve (H) first and
slowly open the hydraulic supply shut-off valve (L).
3. Adjust the flow control valve (Q) to limit the
hydraulic flow to no more than 3 gpm (11 lpm),
which is approximately 60 cycles per minute.
NOTE: If Graco Part No. 236864 hydraulic fluid
control is used, no adjustment is necessary.
4. By adjusting the pressure reducing valve (N),
increase the hydraulic inlet pressure from 50 to
1500 psi (0.34 to 10 MPa, 3.4 to 103 bar).
Increasing the inlet pressure increases the outlet
pressure. Decreasing the inlet pressure decreases
the outlet pressure.
5. Open the drain valve while priming the pump;
close it when the pump is primed.
6. Always use the lowest pressure possible to obtain
the desired results. This reduces pump wear.
Never allow a pump to run dry of the fluid being
pumped. A dry pump quickly speeds up and can
damage itself. If it speeds up, shut off the power
supply to the reciprocator immediately. Refill the
supply container, and prime the pump to eliminate
air.
CAUTION
CAUTION
Maximum Working Temperature
Do not exceed 130_F (54_C) hydraulic oil tem-
perature. The reciprocator seals will wear faster
and leakage may occur if the pump is operated at
higher oil temperatures.

308156 9
Operation
MAXIMUM WORKING PRESSURES
To reduce the risk of serious injury, including
fluid and splashing in the eyes or on the skin,
which may be caused if a component
ruptures:
Never exceed 1500 psi (10 MPa, 102 bar) Maxi-
mum Hydraulic Pressure to the reciprocator.
Never exceed 7500 psi (51 MPa, 517 bar) Maxi-
mum Outlet Pressure from the displacement pump.
Be sure all accessories added to the reciprocator
power supply side have at least a 1500 psi
(10 MPa, 102 bar) Maximum Working Pressure.
Accessories added to the pump fluid outlet side
should have at least a 7500 psi (51 MPa, 517 bar)
Maximum Working Pressure.
The working pressure of the displacement pump
has a 5:1 ratio to the pressure at which the recipro-
cator is operated. Therefore, if the fluid supplied to
the reciprocator is 1000 psi (7 MPa, 69 bar), the
pump fluid outlet pressure will be 5 times the hy-
draulic pressure, or 5000 psi (34 MPa, 345 bar).
WARNING If the Pump Leaks at the Fluid Fittings
Tighten the fittings (1, 5, 58), which are self-sealing
and have replaceable o-rings. If leaking persists,
change the o-rings.
Fig. 4 04478
self-sealing
fitting (1,5,58)
o-ring
(1a,5a,58a)
reciprocator
Shutdown
Relieve the pressure whenever you shut down.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.

10 308156
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. Check; clear obstructions.
Reciprocator damaged. Repair. See page 13.
Pump speeds up or runs erratically. Pump piston and/or intake
valve worn. Relieve pressure. Check and repair. See pages 17 and 18.
Empty supply container. Refill and reprime. 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. Check and repair. See page 17 and 18.
Pump runs but output low on both
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. Check; clear obstructions.
Excessive weepage from weep
tube (B). Worn throat packings. Repair. See page 11.
Hydraulic oil leaks from fittings in the
upper or lower reciprocator blocks
(31,32).
Fittings (1,5,58) are loose, or their
o-rings are worn or damaged. Tighten the self-sealing fittings. If leaking persists, change the o-rings.