Graco Dyna-Star 239882 Operation manual

Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 1991, Graco Inc. is registered to I.S. EN ISO 9001
Dyna–Start
HYDRAULIC RECIPROCATOR AND PUMP
FOR LUBRICATING FLUIDS ONLY
1:1 Ratio Universal Pump and Reciprocator
Model 239882, Series A, Reciprocator Only
1500 psi (10 MPa, 102 bar) Maximum Hydraulic Input Pressure
1500 psi (10 MPa, 102 bar) Maximum Fluid Outlet Pressure
Model 224741, Series C, Stubby Length
1500 psi (10 MPa, 102 bar) Maximum Hydraulic Input Pressure
1500 psi (10 MPa, 102 bar) Maximum Fluid Outlet Pressure
Model 224742, Series C, 55-Gallon Length
1500 psi (10 MPa, 102 bar) Maximum Hydraulic Input Pressure
1500 psi (10 MPa, 102 bar) Maximum Fluid Outlet Pressure
Model 237653, Series B, Stainless Steel Stubby Length Pump
1000 psi (7 MPa, 69 bar) Maximum Hydraulic Input Pressure
1000 psi (7 MPa, 69 bar) Maximum Fluid Outlet Pressure
308155M
Important Safety Instructions
Read all warnings and instructions in this manual. Save these instructions.
See page 26 for Maximum Working Pressures.
Model 224741 shown
Patent No. 4,383,475
Foreign Patents Pending
Patent 1984 Canada
Brevete 1984
06143C
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reciprocator Parts Drawing, Model 239882 18. . .
Reciprocator Parts List, Model 239882 19. . . . . . . .
Displacement Pump Repair,
Models 239882, 224741, and 224742 20. . . . . . . . .
Displacement Pump Parts Drawing and List,
Models 224741, and 224742 22. . . . . . . . . . . . . . . . .
Displacement Pump Repair, Model 237653 23. . . .
Reciprocator Parts Drawing/List,
Model 237653 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Parts Drawing and List,
Model 237653 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions and Mounting Hole Layout 27. . . . . . . .
Graco Standard Warranty 28. . . . . . . . . . . . . . . . . . .
Graco Phone Number 28. . . . . . . . . . . . . . . . . . . . . . .
Parts

2 308155
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 you operate 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.
Check the Technical Data section on page 26 for the maximum hydraulic input pressure and the
maximum fluid outlet pressure of your pump model.
DUse fluids and solvents that are compatible with the equipment wetted parts. Refer to the
Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s
warnings.
DDo not kink or overbend hoses or use hoses to pull equipment.
DRoute hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose 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

308155 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.
FLUID 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 9 if the grease fitting coupler clogs and before
cleaning, checking, or servicing the equipment.
DTighten all fluid connections before you operate 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 308155
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
DKeep clear of all moving parts when you start or operate the pump.
DBefore you service the equipment, follow the Pressure Relief Procedure on page 9 to prevent
the equipment from starting unexpectedly.
WARNING
WARNING
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 8.
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.
DKeep a fire extinguisher in the work area.

308155 5
Installation
Fig. 1
KEY
ASuction hose
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
XLow-level cut-off valve
YThermal Relief Kit (required)
Part No. 237904
Typical Installation of a
Suction Feed System
A
BC
D
EFGHJKLMN
P
Q
R
ST
U
W
*Included in Hydraulic Fluid Control Kit 236864, which can be ordered separately.
X
Y
01843
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.

6 308155
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.
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 or the pump fluid outlet side must have
at least a 1500 psi (10 MPa, 102 bar) maximum
working pressure for models 239882, 224741, and
224742, and at least a 1000 psi (7 MPa, 69 bar)
maximum working pressure for model 237653.
WARNING
Pump Accessories
DA suction hose kit (A ) , Part No. 236054, is
available for siphoning from 55 gallon
containers.
DIntake tube (not shown). To install, apply
Rtape to the female threads at the top
of the tube. Screw the tube tightly into the
intake housing of the stubby pump.
DLow-level cut-off valve (X), Part No. 203688,
closes the pump intake when the fluid level is
low, causing the pump to stall to avoid running
dry. To install, screw the valve into the bottom
of the pump intake tube or the suction tube.
DA pump outlet drain valve (D), Part No.
210658, is installed close to the pump fluid
outlet to help relieve fluid pressure in the pump
when the pump is shut off.
DThermal Relief Kit (Y), Part No. 237904.
Install at the pump fluid outlet.
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 the system is
shut down and if the outlet hose gets clogged. In-
stall the valve close to the pump outlet.
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 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 changing the 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.
PTFE

308155 7
Installation
Hydraulic Lines
NOTE: Refer to Fig. 1 to locate the parts mentioned
below.
DShut-off valves (H and L) are installed in the
hydraulic supply and return lines. Order Part No.
108458 for 1/2 npt(f) supply lines and 108537 for
3/4 npt(f) return lines.
DDrain Line. Remove the plug (59) from the pump
adapter, and install a 1/8–27 npt(f) tube fitting and
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
06146C
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.

8 308155
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 the right. 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 ground wire to a true earth ground. See Fig. 3.
To order a ground wire and clamp, order Part No.
222011.
Fig. 3
Y
06147C
Z

308155 9
Operation
Pressure Relief Procedure
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 you use 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 on page 26. 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 (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),
adjust the hydraulic inlet pressure from 50 to 1500
psi (0.34 to 10 MPa, 3.4 to 102 bar) for models
239882, 224741, and 224742. Increasing the inlet
pressure increases the outlet pressure.
Decreasing the inlet pressure decreases the outlet
pressure.
NOTE: For model 237653, adjust the hydraulic
inlet pressure from 50 to 1000 psi (0.34 to 7 MPa,
3.4 to 69 bar).
5. 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.
To prevent the pump from running dry, use a low-
level cutoff valve (X). See Fig.1 on page 5.
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.

10 308155
Operation
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:
DFor models 239882, 224741, and 224742,
never exceed 1500 psi (10 MPa, 102 bar)
Maximum Hydraulic Pressure to the
reciprocator or Maximum Outlet Pressure from
the displacement pump.
DFor model 237653, never exceed 1000 psi
(7 MPa, 69 bar) Maximum Hydraulic Pressure
to the reciprocator or Maximum Outlet Pressure
from the displacement pump.
DBe sure all accessories added to the
reciprocator power supply side or the pump fluid
outlet side have at least a 1500 psi (10 MPa,
102 bar) Maximum Working Pressure for
models 239882, 224741, and 224742;and at
least a 1000 psi (7 MPa, 69 bar) Maximum
Working Pressure for model 237653.
DThe maximum working pressure of the
displacement pump is directly proportional to
the pressure at which the reciprocator is
operated. Therefore, if the fluid supplied to the
reciprocator is 1000 psi (7 MPa, 69 bar), the
pump fluid outlet pressure will also be 1000 psi
(7 MPa, 69 bar).
WARNING
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 9.
If the Pump Leaks at the Fluid Fittings
Fig. 4
04478
self-sealing fitting
(1,5,58)
o-ring
reciprocator
Models 239882, 224741, and 224742: Tighten
the fittings (1, 5, 58), which are self-sealing and
have replaceable o-rings. If leaking persists,
change the o-rings.
Model 237653: Tighten the fittings (B or K).
These fittings are self sealing and have
replaceable o-rings. If leaking persists, change
the o-rings.
self-sealing
fitting (B or K)
reciprocator
o-ring