Graco Dyna-Star 77X000 User manual

332514J
Instructions
Dyna-Star®HP and
HF Pump
Provides lubricant flow and pressure to operate a single line automatic lubrication
system. For automatic lubrication systems only. For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
Models: Page 2
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
EN

Models
2332514J
Models
Pump
Models
Tube in
Tube
HP
Pump
HF
Pump
Vent
Valve
Compatible Reservoirs Maximum Working Pressure
35/60
Pound
90/120
Pound
400
Pound
3500 psi
24.1 MPa, 241 bar
5000 psi
34.47 MPa, 344 bar
77X000 X X X
77X001 X X X X
77X002 X X X X
77X003 X X X X
77X011 X X X X X
77X012 X X X X X
77X013 X X X X X
77X014 X X X
77X015 X X X
77X016 X X X

Warnings
332514J 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.
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.
WARNINGWARNINGWARNING
WARNING

Warnings
4332514J
PRESSURIZED EQUIPMENT HAZARD
Over-pressurization can result in equipment rupture and serious injury.
• A pressure relief valve is required at each pump outlet.
• Follow Pressure Relief Procedure in this manual before servicing.
PRESSURIZED ALUMINUM PARTS HAZARD
Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical
reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or prop-
erty damage.
• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material sup-
plier for compatibility.
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 MSDS 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 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.
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.
WARNINGWARNINGWARNING
WARNING

Warnings
332514J 5
BURN HAZARD
Equipment surfaces and fluid that’s 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, 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 manufacturers.
WARNINGWARNINGWARNING
WARNING

Typical Installation: Injector System
6332514J
Typical Installation: Injector System
The installation shown in below is only a guide for selecting and installing system components. Contact your Graco
distributor for assistance in planning a system to suit your needs.
Key:
A Lubricant output connection
B Pump
C Ignition switch*
D High-pressure lubricant supply lines*
E Injector banks*
F Lubrication controller*
G Fill port (for reference only; non-tube-in-tube models only)
H Overflow port (for reference only)
J Breather (for reference only)
K Reservoir / Tank
L Vent Valve (for reference only)
M Motor
*User provided
FIG. 1
E
D
C
F
B
H
K
G
FrontBack
Low Reservoir
Level Switch
(Level Indicator,
optional)
Pressure Switch
for System Control
Remote Alarm Device
(Light or Horn)
(user provided
Controller
Capabilities
J
K
L
A
M
Motor Control
Board
Pump Power
Pump Signal
Vent Valve

Typical Installation: Series Progressive System
332514J 7
Typical Installation: Series Progressive System
The installation shown below is only a guide for selecting and installing system components. Contact your Graco dis-
tributor for assistance in planning a system to suit your needs.
Key:
A Lubricant output connection
B Pump
C Ignition switch*
D High-pressure lubricant supply lines*
E Primary metering device*
F Lubrication controller*
G Fill port (for reference only; non-tube-in-tube models only)
H Overflow port (for reference only)
J Breather (for reference only)
K Reservoir / Tank (for reference only)
L Secondary metering device
M Motor
N Bearing
*User provided
FIG. 2
E
D
C
F
B
H
K
G
FrontBack
Low Reservoir
Level Switch
(Level Indicator,
optional)
Pressure Switch
for System Control
Remote Alarm Device
(Light or Horn)
(user provided
Controller
Capabilities
J
K
A
M
L
N
N
L
N
N
Motor Control
Board
Pump Power
Pump Signal

Installation
8332514J
Installation
Pressure Relief
Follow the Pressure Relief Procedure whenever
you see this symbol.
To relieve pressure in the system, use two wrenches
working in opposite directions on pump outlet fitting to
slowly loosen fitting only until fitting is loose; no more
lubricant or air is leaking from fitting as shown in FIG. 3.
Pump Module
Reference numbers used in the following instructions
refer to Parts, page 35. Upper case reference letters
used in the following instructions refer to Typical Instal-
lation Drawings provided on pages 6 and 7.
NOTE:
• Tank / reservoir covers and reservoirs are available
from Graco. Contact your Graco Distributor or
Graco Customer Service for assistance ordering
these parts. See Parts, page 38 for a complete list
of accessories.
• Before installing pump on tank / reservoir, use bolts
to secure tank / reservoir to it’s installation location.
• Install tank / reservoir cover on tank / reservoir.
Tighten screws to secure cover to tank / reservoir.
1. Remove pump mounting screws (a) and washers
(b) from tank / reservoir cover. Save these parts.
Gasket (c) should not be removed from the cover.
These parts will be used to install the pump to the
tank / reservoir cover for reassembly.
2. Loosen bolts (128) and remove cover (126) from
Dyna-Star pump (FIG. 5).
3. Remove protective cap (d) from pump down-tube
(208) (FIG. 6). Discard cap. You will not use it again.
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.
FIG. 3
FIG. 4: 120 Pound Cover Shown
FIG. 5
a
b
c
126
128

Installation
332514J 9
4. Verify gasket (c) is in place on top the reservoir
cover, laying flat and that the holes (e) in the gasket
align with the holes in the cover (FIG. 7).
5. Install pump down-tube through opening in the cen-
ter of the gasket and tank / reservoir cover and into
tank / reservoir.
6. Align holes in pump base with holes in tank / reser-
voir cover (FIG. 8). Securely fasten pump to tank /
reservoir cover using screws (a) and washers (b)
removed in Step 1, page 8.
NOTE: When the pump is correctly installed on the
Graco tank, the breather (J) will be below the control
box (115) as shown in FIG. 9.
7. Reinstall cover (126) using bolts (128). Use a
wrench to tighten bolts securely (FIG. 10).
FIG. 6
FIG. 7
HEAVY EQUIPMENT HAZARD
Lifting or moving heavy equipment incorrectly can
cause serious injury. To avoid serious injuries, such as
muscle strain or back injuries, when moving pump
always use a lifting aid secured to the pump lift ring .
See Technical Data, included in the pump instruction
manual for pump weight information.
208
d
c
ee
e
FIG. 8
FIG. 9
NOTICE
To prevent damage to the unit:
• Check breather (J) vent for proper operation
before filling reservoir.
• Open overflow port (H) before filling reservoir to
visually inspect lubrication level.
• Do not fill reservoir beyond overflow port (H).
• Do not use breather vent as a port to fill
reservoir.
a
b
J
115
133

Wiring
10 332514J
8. Connect the timer/controller (F) (user supplied, if
used).
9. Connect High Pressure Lubricant Supply Line (D) to
the Lubricant Output Connection (0) (FIG. 11) on the
Vent Valve or Manifold.
NOTE: The High Pressure Lubricant Supply Line
(D) is disconnected from the Lubricant Output Con-
nection (0) during Priming, page 15.
Wiring
Grounding
System Configuration and Wiring
NOTE: Cable wiring harness kits are available from
Graco. See Parts page 38 for a complete list of available
kits.
Fuses
FIG. 10
FIG. 11: Lubricant Outlet Connection
126
128
0
D
The equipment must be bonded (grounded)
directly to the truck. Grounding reduces the risk of
static shock due to static build up on the
equipment.
NOTICE
Fuses (user supplied) are required on all models. To
avoid equipment damage:
• Never operate the Dyna-Star Pump models without
a fuse installed.
• A fuse of the correct voltage and amperage must
be installed in line with the power entry to the sys-
tem. Graco recommends using 35A fuses.