Graco Dyna-Star 77X100 Use and care manual

Instructions, Repair and Parts
Dyna-Star®HP
Pump System 332540B
Provides lubricant flow and pressure to operate a single line parallel automatic lubrication
system. For automatic lubrication systems only.
Not approved for use in explosive atmospheres or hazardous locations.
Graco Tank Injector Lubrication Systems
3500 psi (24.1 MPa, 241 bar) Maximum Working
Pressure
Models
All models include Tube-in-Tube design, vent valve,
cover and tank.
Important Safety Instructions
Read all warnings and instructions in this
manual and the Dyna-Star HP and HF
Pump instruction manual. Save all
instructions.
System
Models
Size Dip
Stick
35/60
Pound
90/120
Pound
77X100 X X
77X101 X X
EN

Warnings
2332540B
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.
WARNINGWARNINGWARNING
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
332540B 3
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.
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
manufacturer’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
4332540B
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
332540B 5
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 outlet connection
B Pump
C Ignition switch*
D High-pressure lubricant supply lines*
E Injector banks*
F Lubrication controller*
G Fill port
HOverflowport
J Breather
K Reservoir
L Vent Valve
M Motor
N Dip Stick
*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
A
M
N

Installation
6332540B
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 and no
more lubricant or air is leaking from fitting as shown in
FIG. 2.
•Read and follow instructions supplied with each sys-
tem component.
•Reference letters used in the following Installation
instructions, refer to Typical Installation Key, page 5.
Wiring
Grounding
System Configuration and Wiring
NOTE: Cable wiring harness kits are available from
Graco. See Parts page 11 for a complete list of available
kits.
Fuses
Reservoir Installation
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. 2
COMPONENT RUPTURE HAZARD
The maximum working pressure of each component
in the system may not be the same. To reduce the
risk of overpressurizing any component in the sys-
tem, be sure you know the maximum working pres-
sure of each component. Never exceed the maximum
working pressure of the lowest rated component in
the system. Overpressurizing any component can
result in rupture, fire, explosion, property damage and
serious injury.
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 with-
out a fuse installed.
• A fuse of the correct voltage and amperage must
be installed in line with the power entry to the
system. Graco recommends using 35A fuses.
HEAVY EQUIPMENT HAZARD
Equipment is heavy. To avoid injury:
• Be sure unit is securely mounted before operation.
• Do not lift pressurized equipment.
• 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, in the pump
instruction manual for pump weight.

Operation
332540B 7
1. Mount Reservoir on sturdy, flat surface. Note loca-
tion of Fill Port (G) and Lubricant Outlet Connection
(A) for easy access once installed.
2. Connect High Pressure Lubricant Supply Line (D) to
the Lubricant Outlet Connection (A).
3. Ground system (see Grounding). Mount reservoir
to grounded chassis member.
Pump Installation
Pump installation instructions are provided in the
Dyna-Star HP or HF Pump instruction manual 332514
provided with your system.
Vent Valve Kit
The vent valve is used to reduce system pressure and
allow the injector to reset. When energized, grease is
pumped out through the outlet port (marked 0) on the
vent valve. When de-energized, it vents pressure inter-
nally to tank.
Refer to the Dyna-Star HP or HF Vent Valve Kit manual
332515 for installation and operation instructions.
Operation
•Read and follow instructions supplied with each sys-
tem component.
•Reference letters used in the following Installation
instructions, refer to Typical Installation Key, page 5.
Start-up
Priming
1. After reservoir/tank is completely filled, remove high
pressure lubricant supply line (D) from the outlet.
2. Connect power to pump.
3. Start pump and run pump until all air has been
expelled and fluid flow is continuous.
4. Reconnect the high pressure lubricant supply line
(D) to outlet.
Do not insert finger into the overflow port while
filling a reservoir equipped with a follow plate. Injury
or amputation could result.

Operation
8332540B
Filling Reservoir
1. Connect lubricant supply hose from remote filling
station pump to Fill Port (G).
2. Remove plug from Overflow Port (H).
3. Slowly turn on supply lubricant until level of lubricant
reaches Overflow Port (H).
NOTE: For systems with a follower plate, fill unit until the
follower plate reaches the Overflow Port (H).
4. Disconnect lubricants supply hose from Fill Port (G).
5. Plug Fill Port (G) and Overflow Port (H).
Shutdown
For normal system shut down, disconnect power by
turning off the ignition switch (C).
NOTICE
To prevent damage to the unit:
• Check Breather vent (J) for proper operation
before filling reservoir.
• Open Overflow Port (H) before filling for visual
inspection of lubricant level.
• Do not fill beyond Overflow Port (H).
• Do not use Overflow Port (H) to fill reservoir.
NOTICE
Never allow pump to run dry of the fluid being pumped.
Running a pump dry can damage the pump.

Parts List
332540B 9
Parts List
Model 77X100: Dyna-Star Pump, 60#, Dip Stick, Reservoir, Cover, Vent Valve
Model 77X101: Dyna-Star Pump, 90#, Dip Stick, Reservoir, Cover, Vent Valve
Cable Harness Kits
Ref.
No. Part No. Description Qty
1 77X011 KIT, pump and vent valve,
includes 1a and 1b, Dyna-Star
60#, models 77X100, see instruc-
tion manual 332514
1
77X012 KIT, pump and vent valve,
includes 1a and 1b, Dyna-Star
90#, models 77X101, see instruc-
tion manual 332514
1
1a PUMP 1
1b VENT VALVE, see instruction
manual 332519
1
3 77X535 KIT, reservoir, 60# grease,
models 77X100
1
77X536 KIT, reservoir, 90# grease,
models 77X101
1
3a 100737 . PLUG, pipe 2
3b 108126 . TEE, pipe 1
3c 110996 . NUT, flanged, hex 8
3d 111800 . SCREW, cap, flange head 4
3e 115254 . BREATHER 1
3f 194868 . GASKET, cover 1
3g 15R105 . PAIL, reservoir, 60#, included in
kit 77X535
1
194907 . PAIL, reservoir, 90#, included in
kit 77X536
1
3h 16V394 . COVER, reservoir 1
3i 104663 . PLUG, pipe (not shown) 1
3j 109114 . SCREW, cap 4
3k 15M442 . GASKET, pump 1
3l 104572 . WASHER, lock, spring 4
3m 16V396 . SEAL 1
3n 16V395 . COVER 1
4 77X531 KIT, dip stick, 60#, grease, see
instruction manual 332515
1
77X530 KIT, dip stick, 90#, grease, see
instruction manual 332515
1
Part No. Description
77X527 KIT, cable harness, receptacle (female)
77X528 KIT, cable harness, plug (male)
77X529 KIT, cable, harness, receptacle and vent valve

Parts Drawing
10 332540B
Parts Drawing
Model 77X100: Dyna-Star Pump, 60#, Dip Stick, Reservoir, Vent Valve
Model 77X101: Dyna-Star Pump, 90#, Dip Stick, Reservoir, Vent Valve
1a
1b 4
3e
3d
3h
3f
3k
3c
3a
3g
3b
3j
3a
3d
3m/3n
3l