Graco Dyna-Star 25A189 Use and care manual

3A3005C
Instructions, Repair and Parts
Dyna-Star®
Hydraulic Reciprocator and
High Pressure Pump
High Pressure Pump and Reciprocator used for dispensing grease in wire-
line applications for oil well services.
900 psi (6.2 MPa, 62.1 bar)) Maximum Hydraulic Input Pressure
10,000 psi (69 MPa, 689 bar) Maximum Fluid Outlet Pressure
Model 25A189: 120 lb Drum Length
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
EN

Warnings
23A3005C
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
WARNINGWARNING
SKIN INJECTION HAZARD
High-pressure fluid from 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 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 gas-
oline.
• 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
3A3005C 3
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 Safety Data Sheet (SDS) 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 man-
ufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and cre-
ate 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.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equip-
ment, 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 Sheet (SDS) 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 severe
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, includ-
ing 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 manufac-
turer.
WARNING
WARNINGWARNING

Installation
43A3005C
Installation
Typical Installation
The following Typical Installation is only provided as a guide for selecting and installing system components and
accessories. Mount pump to suit the type of installation planned. For assistance in designing a system to suit your
needs, contact your Graco Distributor.
Key:
A Drain line
B Weep tube
C Fluid outlet line
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” -16 JIC (37° flare)
L Supply line shut-off valve (required)
M Pressure gauge
N Pressure reducing valve (required in systems over 900 psi
[6.2 MPa, 62.1 bar)])
P Accumulator
R Flow control valve (required in systems over 3 gpm [11
lpm])
S Hydraulic supply line
TCheckvalve
U Variable volume pressure compensated pump
V Hydraulic power supply
WCheckvalve
Y Pressure gauge
ZCheckvalve
AA Shut-off valve
BB Drain tube
CC 1/2 NPT outlet adapter (included)

Installation
3A3005C 5
Installation Instructions
Pump Accessories
Pump Outlet Drain Valve (D): helps relieve fluid pres-
sure in pump when pump is shut off. Install valve close
to pump fluid outlet.
Pump Outlet Adapter (CC): pump is supplied with an
adapter to female 1/2 NPT. To connect directly to pump,
remove the adapter and use a medium 3/16-16 UN
medium pressure, coned and threaded connection.
Hydraulic Power Supply
See Typical Installation, page 4.
The hydraulic power supply (V) must have a pressure
reducing valve and a pressure-compensated flow con-
trol.
A flow control valve (R) 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.
Hoses: Use a minimum 1/2 inch supply line (S) and
minimum 3/4 inch return line (F) on the reciprocator.
Contact your Graco representative for details of line siz-
ing.
Pressure Reducing Valve (N): circulates excess
hydraulic fluid pressure back to the hydraulic power sup-
ply. Install this valve (N) in the hydraulic supply line with
a drain hose (A) teed into the hydraulic return line (F).
Limit supply pressure to a maximum 900 psi (6.2 MPa,
62.1 bar)).
Accumulator (P): reduces hammering effect caused by
the reciprocator 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.
Mount pump securely so it cannot move around
during operation. Failure to do so could result in per-
sonal injury and/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 component ruptures, all
accessories added to the reciprocator power supply
side must have at least 900 psi (6.2 MPa, 62.1 bar))
maximum working pressure.
All accessories added to the pump fluid outlet side
must have at least 10,000 psi (69 MPa, 689 bar)
maximum working pressure.
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
900 psi (6.2 MPa, 62.1 bar).

Installation
63A3005C
Grounding
•Pump: Use ground wire and clamp as shown in
FIG. 1. 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 (FIG. 1)
To ground pump:
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 the frame of the truck.
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. 1
Z

Operation
3A3005C 7
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Turn off hydraulic power supply (V).
2. Close supply line shut-off valve (L).
3. Open pump drain valve (D).
4. Verify pressure has been relieved by checking pres-
sure gauge (Y).
5. Close shut-off valve (AA).
NOTE: Leave the drain valve (D) open until you are
ready to dispense again.
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
26. Flush until clean solvent comes out of hose.
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 dispensing and before
cleaning, checking, or servicing the equipment.
COMPONENT RUPTURE HAZARD
Overpressurizing any component can result in seri-
ous injury or property damage as a result of rupture,
fire, and/or explosion.The maximum working pres-
sure 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 to or higher than the pump
rating.
• Do not exceed the maximum output pressure. The
pump has a rated ratio of 10:1. However, it is
capable of reaching stall pressures equal to 11.1
times the hydraulic input pressure. To calculate
the fluid output pressure, multiply the hydraulic
pressure shown on the hydraulic control module
gauge by 11.1.
For example:
900 psi hydraulic x 11.1 = 10,000 psi fluid output
6.2 MPa hydraulic x 11.1 = 69 MPa fluid
output
62.05 bar hydraulic x 11.1 = 689 bar fluid output
• Do not exceed the maximum pump cycle rate.
• Regulate hydraulic pressure to the pump so that
no fluid line component or accessory is overpres-
surized.

Operation
83A3005C
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 (R) 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 900 psi (0.34 to
6.2 MPa, 3.4 to 62.1 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.
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 900 psi (6.2 MPa, 62.1 bar) Maxi-
mum Hydraulic input Pressure to the reciprocator.
• Never exceed 10,000 psi (69 MPa, 689 bar) Max-
imum Outlet Pressure from the displacement
pump.
• Accessories added to the pump fluid outlet side
should have at least a 10,000 psi (69 MPa, 689
bar) Maximum Working Pressure.
• Read and understand COMPONENT RUPTURE
HAZARD instructions, page 7.
FIG. 2
sealing
fitting (1, 5, 60)
reciprocator
o-ring
(1a, 5a,60a)
ti04478

Troubleshooting
3A3005C 9
Troubleshooting
Problem Cause Solution
Pump does not run. Closed dispense valve. Pump only runs with valve open.
Hydraulic supply pressure too low -
see gauge (M).
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 runs 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 leakage of lubricant from
weep tube (B), page 4 or breather,
page 10.
Worn u-cup packing (44), (Parts
page 24)
Repair.
Excessive leakage of hydraulic fluid
from weepage tube (B), page 4 or
breather, page 10.
Worn V-block packing (16), (Parts
page 24)
Repair.
Hydraulic oil leaks from fittings in the
upper or lower reciprocator blocks
(31, 32) [Parts page 24].
Fittings 1, 5, 58, (Parts, page 24), are
loose, or their o-rings are worn or
damaged.
Tighten the self-sealing fittings. If
leaking persists, change o-rings.
Leak at output pressure relief hole
(FIG. 4, page 10).
Wrong style fitting. Install correct fitting.
Fitting is loose Tighten fitting.

Service
10 3A3005C
Service
NOTE: The reference letters used in the following Ser-
vice instructions refer to the Typical Installation illustra-
tion provided on page 4.
The reference numbers used in the following Service
instructions refer to the Parts pages beginning on page
22.
Pump Leaks at the Fluid Fittings
Tighten fittings (1, 5, 60; FIG. 3) which are self-sealing
and have replaceable o-rings. If leaking persists, change
o-rings.
Removing Displacement Pump
from Reciprocator
Disassembly
1. Flush pump.
2. Relieve pressure, page 7.
3. Clamp reciprocator/pump assembly in a brass-jaw
vise.
4. Disconnect fluid outlet hose (C) (Typical Installation,
page 4) from displacement pump.
5. Slowly loosen hydraulic supply fitting (60) and return
fitting (5) (FIG. 4). Remove hoses.
6. Install plugs in tube fittings and hose ends.
FIG. 3
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.
sealing
fitting (1, 5, 60)
reciprocator
o-ring
(1a, 5a,60a)
ti04478
FIG. 4
43
5
60
breather
pressure
relief hole