Graco Dyna-Star 224912 User manual

Instructions
Dyna-Star™Hydraulic
Reciprocator and Pump 308156S
EN
For lubricating fluids only. For professional use only.
5:1 Ratio Universal Pump and Reciprocator
1500 psi (10 MPa, 102 bar) Maximum Hydraulic Input Pressure
7500 psi (51 MPa, 517 bar) Maximum Fluid Outlet Pressure
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
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.

2308156S
Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pump Accessories . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic Power Supply . . . . . . . . . . . . . . . . . . . 7
Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 9
Before Starting the Pump . . . . . . . . . . . . . . . . . . 9
To Start the Pump . . . . . . . . . . . . . . . . . . . . . . . . 9
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
If the Pump Leaks at the Fluid Fittings . . . . . . . 10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Replacing the Throat Seals . . . . . . . . . . . . . . . . 12
Disconnecting the Reciprocator and Displacement
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Reciprocator Repair . . . . . . . . . . . . . . . . . . . . . 13
Displacement Pump Repair . . . . . . . . . . . . . . . 18
Parts - Displacement Pumps . . . . . . . . . . . . . . . . 20
Parts - Reciprocator . . . . . . . . . . . . . . . . . . . . . 21
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Dimensions and Mounting Hole Layout . . . . . . . 25
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . 26

Warnings
308156S 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.
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.
•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.

Warnings
4308156S
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 MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• 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.
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 MSDSs 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 chemically impermeable gloves when spraying, dispensing, or cleaning equipment.
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.
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. This 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
308156S 5
Installation
Grounding
Pump: Use ground wire and clamp as shown in FIG. 1.
Hydraulic hose and fluid outlet hoses: use only elec-
trically conductive hoses.
Hydraulic power supply: Follow manufacturer’s recom-
mendations.
Any pails used when flushing: Use only metal,
grounded pails when flushing. Make firm metal-to-metal
contact between the 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
ground wire to a true earth ground. (FIG. 1)
The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides an escape wire for the electric
current.
FIG. 1
Y
Z

Installation
6308156S
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” I.D. (required)
G Hydraulic outlet, 1/2 npt
H Return line shut-off valve, minimum 3/4” (required)
J Hydraulic inlet, 1/2 npt
K Tee, 3/4 npt
L *Supply line shut-off valve
M *Pressure gauge
N *Pressure reducing valve (required in systems over 1500
psi [10.2 MPa, 102 bar])
P Accumulator
R *Flow control valve (required in systems over 3 gpm [11
lpm])
S Hydraulic supply line
T Check valve
U Variable volume pressure compensated pump
V Hydraulic power supply
W Drain line, accumulator
* Included in Hydraulic Fluid Control Kit, 236864, which can be ordered separately.
Although the installation shown in FIG. 2 is only a guide for selecting and installing system components and accesso-
ries, some equipment is required, as noted in the key. For assistance in designing a system to suit your needs, con-
tact your Graco distributor.
Mount the pump to suit the type of installation planned.
FIG. 2: Typical Installation
A
B
C
D
E
FGHJK
L
M
N
P
R
S
TU
V
W

Installation
308156S 7
Pump Accessories
• Follower plate (A) ensures a good prime. Place the
plate on the grease and rotate while pressing firmly
to level the material.
• Pump outlet drain valve (D) helps relieve fluid pres-
sure in the pump when the pump is shut off. Install
the valve close to the pump fluid outlet. Order Part
No. 111229, valve.
Hydraulic System
The hydraulic supply system must be kept clean at all
times to reduce the risk of damaging the reciprocator
hydraulic power supply. Blow out all hydraulic lines with
air, flush thoroughly with solvent, and blow out with air
again before you connect the lines to the reciprocator.
Always plug the hydraulic inlets, outlets, and lines when
you disconnect them for any reason to avoid introducing
dirt and other contaminants into the system.
Carefully follow the manufacturer’s recommendations on
cleaning the reservoir and filter and periodically chang-
ing the hydraulic fluid.
Hydraulic Power Supply
The hydraulic power supply system (V) must have a
pressure reducing valve and a pressure-compensated
flow control. A flow control valve (R) 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 (R), are including in the Hydraulic Fluid Control Kit,
236864, which can be ordered separately.
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 supply
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.
NOTICE
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 the system is
shut down and if the outlet hose gets clogged. Install
the valve close to the pump outlet.
Limit Fluid Flow to Reciprocator
To reduce the risk of over-pressurizing 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 (10.2 MPa, 102 bar).

Installation
8308156S
Hydraulic Lines
Refer to FIG. 2 for the parts mentioned in the following
instructions.
• Shut off valves (H and L): Installed in the hydraulic
supply and return lines.
• Drain 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. (FIG. 3)
• Hose: Use a minimum 1/2” supply line (R) and mini-
mum 3/4” 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 teed into the hydraulic return
line (F). Limit supply pressure to a maximum of
1500 psi (10.2 MPa, 102 bar).
• Accumulator (P): Reduces the hammering effect
caused by the motor when it reverses direction.
• Fluid-filled pressure gauge (M): Monitors hydraulic
pressure to the reciprocator during start up. Use the
gauge for initial adjustment of the reciprocator. It
can be removed after adjustment is made.
FIG. 3
59

Operation
308156S 9
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Shut off the hydraulic power supply.
2. Close the supply line shut-off valve (L, FIG. 2).
3. Open the dispensing valve to relieve pressure.
4. Open the pump outlet drain valve and have a con-
tainer ready to catch the drainage.
5. Close the return line shut-off valve (H).
NOTE: Leave the drain valve open until you ar 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 Starting 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.
2. Flush the pump before you use it for the first time to
remove the light oil that was left in after factory test-
ing 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 24. 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), and slowly
open the hydraulic supply shut-off valve (L).
3. Adjust the flow control valve (R) to limit the hydraulic
flow to no more than 3 gpm (11 lpm), which is
approximately 60 cycles per minutes.
NOTE: If Graco Part No. 236864 hydraulic fluid control
is used, no adjustment is necessary.
4. By adjusting the pressure reducing valve (N), adjust
the hydraulic inlet pressure from 50 to 1500 psi
(0.34 to 10.2 MPa, 3.4 to 102 bar). Increasing the
inlet pressure increases the outlet pressure.
Decreasing the inlet pressure decreases the outlet
pressure.
5. Always use the lowest pressure possible to obtain
the desired results. This reduces pump wear.
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.
NOTICE
Always use Graco approved hydraulic oil or equiva-
lent, Part No. 169236 (5 gallon) or 207428 (1 gallon).
Do not substitute lower grade oil.
NOTICE
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 sup-
ply to the reciprocator immediately. Refill the supply
container, and prime the pump to eliminate air.

Operation
10 308156S
Shutdown
Relieve the pressure whenever you shut down. See
Pressure Relieve Procedure on page 9.
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.
10
FIG. 4
self-sealing
fitting (1,5,58)
o-ring
(1a,5a,58a)
reciprocator