Graco Dyna-Star A Series Operation manual

308–390
Rev. C
Supersedes Rev. A
Includes Rev. B
First choice when
quality counts. 
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
Dyna-Star
HYDRAULIC RECIPROCATOR & PUMP
1500 psi (10 MPa, 103 bar) Maximum Hydraulic Input Pressure
375 psi (2.6 MPa, 26 bar) Maximum Fluid Outlet Pressure
1/4:1 RATIO UNIVERSAL PUMP AND RECIPROCATOR
Model 236–753, Series A, stubby length
RECIPROCATOR ONLY
Model 236–751, Series B
WARNING
The pump is designed to dispense lube products
only . Any other fluids can cause unsafe operating
conditions and result in component rupture, fire or
explosion which could cause serious injury , includ -
ing fluid injection.
Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reciprocator Repair 14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Repair 18. . . . . . . . . . . . . . . . . . . . .
Parts List & Drawing
Universal 1/4:1 Ratio Displacement Pump 19. . . . . .
Reciprocator 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensional Drawing and Mounting Hole Layout 23. .
Warranty 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 24. . . . . . . . . . . . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1994, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
Model 236–753 shown
Patent No. 4,383,475
Foreign Patents Pending
Patent 1984 Canada
Brevete 1984


 
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 .
D This equipment is for professional use only .
D
Read all instruction manuals, tags, and labels before you operate the equipment.
D Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor .
D Do not alter or modify this equipment.
D Check equipment daily . Repair or replace worn or damaged parts immediately .
D Do not exceed the maximum working pressure of the lowest rated component in your system.
This equipment has a
1500 psi (10 MPa, 103 bar) maximum hydraulic input pressure and
375 psi (2.6 MPa, 26 bar) maximum fluid outlet pressure.
D Use fluids and solvents that are compatible with the equipment wetted parts. Refer to the
T echnical Data section of all equipment manuals. Read the fluid and solvent manufacturer ’s
warnings.
D
Handle hoses carefully . Do not pull on hoses to move equipment.
D Route 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).
D
Do not lift pressurized equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.
WARNING
WARNING


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.
 Know the specific hazards of the fluid you are using.
 Store hazardous fluid in an approved container . Dispose of hazardous fluid according to all local,
state, and national guidelines.
 Always wear protective eyewear , gloves, clothing, and respirator as recommended by the fluid
and solvent manufacturer .
FLUID INJECTION HAZARD
Spray 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 .
 Fluid injected into the skin might look like just a cut, but it is a serious injury . Get immediate
medical attention.

Do not point the dispensing valve at anyone or at any part of the body .

Do not put your hand or fingers over the end of the dispensing valve.
 Do not stop or deflect leaks with your hand, body , glove, or rag.
 Use only extensions and no-drip tips that are designed for use with your dispensing valve.
 Do not use a low pressure flexible nozzle with this equipment.
 Follow the Pressure Relief Procedure on page 8 if the grease fitting coupler clogs and before
cleaning, checking, or servicing the equipment.
T ighten all fluid connections before you operate the equipment.
 Check the hoses, tubes, and couplings daily . Replace worn or damaged parts immediately . Do
not repair high pressure couplings; you must replace the entire hose.
 Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
WARNING
WARNING

4 308-390
MOVING P ARTS HAZARD
Moving parts can pinch or amputate your fingers.
 Keep clear of all moving parts when you start or operate the pump.
 Before you service the equipment, follow the Pressure Relief Procedure on page 8 to prevent
the equipment from starting unexpectedly .
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
.

Ground the equipment and the object being sprayed. Refer to Grounding on page 7.
 If there is any static sparking or you feel an electric shock while using this equipment, stop
spraying immediately . Do not use the equipment until you identify and correct the problem.
 Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
 Keep the spray area free of debris, including solvent, rags, and gasoline.
 Before operating this equipment, electrically disconnect all equipment in the spray area.
 Before operating this equipment, extinguish all open flames or pilot lights in the spray area.
 Do not smoke in the spray area.
 Do not turn on or of f any light switch in the spray area while spraying or while there are any
fumes in the air .

Do not operate a gasoline engine in the spray area.
WARNING
WARNING
United States Government safety standards have been adopted under the Occupational Safety and Health Act.
Y ou should consult these standards––particularly the General Standards, Part 1910.

5308-390
Installation
KEY
AHydraulic Fluid Control, 236–864
(See Manual 308–395)
B Porous Plug (W eep tube optional)
C Fluid Dispenser Outlet
D Drain V alve (Required)
F Hydraulic Return Line
G Hydraulic Outlet, 3/4 npt
H Return Line Shutof f V alve
J Hydraulic Inlet, 3/8 npt
K Hydraulic Supply Line Shutof f
Valve
L Pressure Gauge
M Pressure Reducing V alve
N Flow Control V alve
P Hydraulic Supply Line (Use only
GRACO hydraulic power supply)
Q Material Supply
R Ground Wire (Required)
SW all Mounting Bracket 236–778
(See Manual 308–394)
Typical Installation – Suction Feed System
Fig. 1 03516
R
F
P
A
H
K
M
N
B
J
Q
D
C
L
G
S
The installation shown in Fig. 1 is only a guide. For
assistance in designing a system to suit your needs,
contact your Graco distributor .
Mount the pump to suit the type of installation planned.
See page 22 for
Accessories.
Maximum W orking Pressure of Accessories
T o reduce the risk of serious bodily injury including
fluid injection and splashing in the eyes or on the
skin, which may be caused if a component rup -
tures, all accessories added to the reciprocator
power supply side must have at least a 1500 psi
(10 MPa, 103 bar) maximum working pressure and
those to the pump fluid outlet side must have at
least a 375 psi (2.6 MPa, 26 bar) maximum
working pressure.
WARNING

6 308-390
Installation
Pump Accessories
Suction T ube Kit
A suction tube kit is available for siphoning from 55
gallon containers.
Intake T ube (not shown)
T o install, apply tape to the female threads at
the top of the tube. Screw the tube tightly onto the
intake housing of the stubby pump.
Low-level Cutoff V alve
T o install, screw the low-level cutoff valve into the
bottom of the pump intake tube or the suction tube.
This valve closes the pump intake when the fluid level
is low , causing the pump to stall to avoid running dry .
Ground W ire
A ground wire is required. See Accessories , page 22.
Pump Outlet Drain V alve
Install a drain valve (D) close to the pump fluid outlet to
assist in relieving fluid pressure in the pump when the
pump
is shut of f. See warning below .
Pump Outlet Drain V alve
A pump outlet drain valve (D) is required in your
system. This valve helps relieve pressure in the
displacement pump and hose when shutting down
the system and in case of a clogged outlet hose.
Install the valve close to the pump outlet.
WARNING
CAUTION
Keep The Hydraulic System Clean
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 sol -
vent, and then blow out with air again before con -
necting the lines to the reciprocator .
Always plug the hydraulic inlets, outlets and lines
when disconnecting them for any reason to avoid
introducing dirt and other contaminants into the
system.
Carefully follow the manufacturer ’ s recommenda -
tions on reservoir and filter cleaning, and periodic
changes of hydraulic fluid.
Hydraulic Power Supply
To reduce the risk of overpressurizing the hydraulic
reciprocator , which could cause a rupture and
serious bodily injury , including fluid injection, the
hydraulic power supply must have a means to limit
the incoming fluid pressure developed in the sys -
tem to a maximum of 1500 psi (10 MPa, 103 bar) .
WARNING
PTFE

7308-390
Installation
Hydraulic Fluid Control
Always turn of f the hydraulic supply side valve (K
in Fig. 1) first to avoid possible serious injury or
component damage.
WARNING
The hydraulic fluid control provides pressure
regulation, flow regulation, and pump isolation. See
Fig. 1 for typical installation.
D Pressure Regulation
The hydraulic fluid control reduces the hydraulic oil
pressure to the operating pressure required for the
application.
D
Flow Regulation
The hydraulic fluid control limits the maximum
amount of oil flow to the motor to keep the hydraulic
motor within the recommended cycle rate limit. This
prevents pump runaway
. The limit on the Dyna-Star
is 60 cpm.
D Pump Isolation
The hydraulic fluid control has ball valves on the
supply and return sides of the manifold. The ball
valves isolate the hydraulic fluid control and pump
for servicing without stopping the hydraulic power
supply.
Grounding
T o 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.
D Pump: Use ground wire and clamp as shown to the
right.
D
Hydraulic Hoses and Fluid Outlet Hoses: Use only
electrically conductive hoses.
D Hydraulic Power Supply and Air Compressor:
Follow manufacturer ’ s recommendations.
D Any 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, loosen the grounding lug
locknut (W) and washer (X). Insert one end of a 12 ga
(1.5 mm @ ) minimum ground wire (Y) into the slot in lug
(Z), and tighten the locknut securely
. Connect the other
end of the wire to a true earth ground. See Fig. 2.
T o order a Grounding Wire and Clamp Kit, order Part
No. 222–01 1.
Fig. 2
ZX W
Y
03517

 
Operation
Pressure Relief Procedure
INJECTION HAZARD
The system pressure must be manually
relieved to prevent the system from
starting or spraying accidentally . Fluid
under high pressure can be injected through the
skin and cause serious injury . T o reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you
D Are instructed to relieve the pressure
D Stop spraying
D Check or service any of the system equipment
D Install or clean the nozzle
WARNING
1. Close the supply line shut-of f valve (L in Fig. 1)
and the return line shut-of f valve (H). Shut of f the
hydraulic power supply .
2.
Open the dispensing valve to relieve pressure.
3. Open the pump outlet drain valve, and have a
container ready to catch the fluid.
4. Leave the drain valve open until you are ready to
spray 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. Now clear the
obstruction.
Be sure you always shut of f the hydraulic supply
line shutof f valve (K) first, and then the return line
shutof f valve. This is to prevent overpressurizing
the motor or its seals. When starting up the hy
-
draulic system, open the return line shutof f valve
first.
WARNING
Before Y ou Start The Pump
Recommended Hydraulic Oil
Use Graco-approved Hydraulic Oil or a premium,
ISO grade 46 petroleum-based hydraulic oil con -
taining rust and oxidation inhibitors and anti-wear
agents. See Accessories on page 22.
Before using any other type of oil in this motor ,
contact your Graco distributor . Unauthorized use of
lesser grade oil or substitutes may void the war -
ranty.
Hydraulic Oil W orking Temperature
The recommended hydraulic oil operating tempera -
ture is 80 to 1 15_ F (27 to 45 _ C). The motor
seals will wear faster and leakage may occur if the
pump is operated at higher oil temperatures.
If the hydraulic oil temperature approaches 130 _ F
(54_
C), check the hydraulic fluid supply cooling
system, filters, etc. and clean or repair as needed.
CAUTION
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 using it for the first time to
remove the light oil which 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
T echnical Data on page 23. Flush until clean
solvent comes from the outlet hose.


Operation
Starting the Pump
Maximum W orking Pressures
T o reduce the risk of serious bodily injury includ-
ing fluid injection and splashing in the eyes or on
the skin, which may be caused if a component
ruptures:
Never exceed 1500 psi (10 MPa, 103 bar) Maxi -
mum Hydraulic Pressure to the reciprocator .
Never exceed 375 psi (2.6 MPa, 26 bar) Maxi -
mum Outlet Pressure from the displacement
pump.
Be sure all accessories added to the reciproca -
tor power supply side are capable of at least a
1500 psi (10 MPa, 103 bar) maximum working
pressure and all of those for the pump fluid out -
let side have at least a 375 psi (2.6 MPa, 26 bar)
maximum working pressure .
The maximum working pressure of the displace -
ment pump is directly proportional to the pres -
sure at which the reciprocator is operated.
Therefore, if the fluid supplied to the reciprocator
is 1000 psi (7 MPa, 69 bar), the pump fluid out -
let pressure will be 250 psi (1.7 Mpa, 17.4 bar).
WARNING
1. T urn on the hydraulic power supply .
2.
Open the return line shutoff valve (H) first and
slowly open the hydraulic supply line shutof f valve
(K).
3.
Adjust the hydraulic inlet pressure from 500 to
1500 psi (3.4 to 10 MPa, 34 to 103 bar) with the
pressure reducing valve control adjustment (M) on
the hydraulic fluid control (A). Increasing the inlet
pressure increases the outlet pressure.
Decreasing the inlet pressure decreases the outlet
pressure.
4.
Always use the lowest pressure possible to obtain
the desired results. This reduces pump wear .
NOTE:
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 of
f the
power supply to the reciprocator immediately
. Refill
the supply container and prime the pump to
eliminate air . T o prevent the pump from running
dry , use a low-level cutof f valve.
If the Reciprocator Leaks at the Fluid
Fittings
Tighten the fittings (16, 17, 25), which are self-sealing
and have replaceable o-rings. If leaking persists,
change the o-rings. See Fig. 3.
Fig. 3
SELF-SEALING FIT -
TING (16, 17, 25)
O-RING
RECIPROCATOR
03522
Shutdown and Care
To stop the pump in an emergency , close the supply
line shutof f valve marked STOP.
The normal shutdown procedure is as follows:
1. Relieve the pressure.
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
2. Always shut of f the supply line shutoff valve (K)
first , and then the return line shutof f valve (H).
This is to prevent overpressurizing the reciprocator
or its seals.
NOTE: When starting the hydraulic system, open
the return line shutof f valve (H) first. See page 5.

10 308-390
Troubleshooting
WARNING
T o reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 8.
Note: Check all possible problems and solutions
before disassembling the pump or reciprocator .
PROBLEM CAUSE SOLUTION
Pump will not run. Closed dispense valve. Pump only runs with valve open.
Pressure too low .Increase supply pressure using the
pressure
adjusting valve.
Insuf ficient hydraulic fluid supply .Check hydraulic supply . Adjust to a
maximum
of 3 gpm (1 1 liter/min) flow .
Clogged fluid outlet line, intake
valve,
dispense valve, suction line.
Relieve pressure. Check; clear
obstructions.
Reciprocator damaged. Repair . See page 14 or 17.
Pump speeds up or runs erratically . Pump piston and/or intake
valve worn.
Relieve pressure. Check and repair .
See
page 18.
Empty supply container . Refill and reprime. Do not allow pump
to run dry . Monitor closely or use a low-
level cutof f valve.
Pump runs, but output low on up
and/or
down stroke.
Pump piston and/or intake valve
worn.
Relieve pressure. Check and repair .
See
page 18.
Pump runs but output low on both
strokes.
Insufficient hydraulic fluid supply . Check hydraulic supply .
Pressure too low .Increase supply pressure using the
pressure
adjustment on the control.
Clogged fluid outlet line, intake
valve,
dispense valve, suction line.
Relieve pressure. Check; clear
obstructions.
Excessive weepage from porous
plug
(B).
W orn throat seals.. Repair . See page 12.
Hydraulic oil leaks from fittings in the
upper or lower reciprocator blocks
(53, 47).
Fittings (16,17,25) are loose, or their
o-rings are worn or damaged.
Tighten the self-sealing fittings. If leak -
ing
persists, change the o-rings.