Graco Dyna-Star B Series User manual

Instructions
Dyna-Star™1/4:1 Ratio
Universal Pump and
Reciprocator 308390N
EN
For lubricating fluids only. For professional use only.
Model 236753
Series B, Stubby length
Model 239884
Series A, Reciprocator only
1500 psi (10 MPa, 120 bar) Maximum Hydraulic Inlet
Pressure
375 psi (2.6 MPa, 26 bar) Maximum Fluid Outlet
Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
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, including
fluid injection.
Model 236753 Shown

2308390N
Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic Power Supply . . . . . . . . . . . . . . . . . . . 7
Hydraulic Lines . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 8
Before Starting the Pump . . . . . . . . . . . . . . . . . . 8
Starting the Pump . . . . . . . . . . . . . . . . . . . . . . . . 8
If the Reciprocator Leaks at the Fluid Fittings . . . 9
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Replacing the Throat Seals . . . . . . . . . . . . . . . . 11
Disconnecting Reciprocator and Displacement
Pump and Replacing Throat Seals . . . . . . . 11
Assembly After Replacing Throat Seals . . . . . . 12
Reciprocator Repair . . . . . . . . . . . . . . . . . . . . . 12
Displacement Pump Repair . . . . . . . . . . . . . . . 17
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 22

Warnings
308390N 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.
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
4308390N
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.
• Do not leave the work area while equipment is energized or under pressure.
• 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.
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 MSDSs 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.
• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.
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 flu-
ids containing such solvents.
• Many other fluids may contain chemicals that can react with aluminum. Contact your material sup-
plier for compatibility.
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.
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 manufacturer
WARNING

Installation
308390N 5
Installation
Grounding
Pump: Use ground wire and clamp as shown in FIG. 1.
To order a Grounding Wire and Clamp kit, order Part No.
222011.
Hydraulic hoses and fluid outlet hoses: Use only
electrically conductive hoses.
Hydraulic power supply: Follow manufacturer’s rec-
ommendations.
Any pails used when flushing: Use only metal,
grounded pails when flushing. Make firm metal-to-metal
contact between the metal part of the dispense valve
and the pail. Use the lowest possible pressure.
To grounding the pump: Remove the ground screw (Z)
and insert through the ye of the ring terminal at the 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.
Accessories
Suction Hose Kit, Part No. 236054
A suction tube kit is available for siphoning from 55-gal-
lon containers
Intake Tube (not shown)
To install, apply PTFE 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 Valve, Part No. 203688
To install, screw the low-level cutoff valve into the bot-
tom 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 Wire, Part No. 222011
A ground wire is required.
Pump Outlet Drain Valve, Part No. 210658
Install a drain valve (C) close to the pump fluid outlet to
assist in relieving fluid pressure in he pump when the
pump is shut off.
Thermal Relief Kit, Part No. 235998
Install a Thermal Relief Kit (S) at the pump fluid outlet.
The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides an escape wire for the electric
current.
FIG. 1
Y
Z
NOTICE
Pump Outlet Drain Valve
A pump outlet drain valve (C) is required in the sys-
tem. This valve helps relieve pressure in the displace-
ment pump and hose when shutting down the system
and in case of a clogged outlet hose. Install the valve
close to the pump.

Installation
6308390N
Key:
A Porous plug (weep tube optional)
B Fluid dispenser outlet
C Drain valve (required)
D Hydraulic return line, minimum 3/4 in I.D. (required)
E Hydraulic outlet, 3/4 npt
F Return line shutoff valve, minimum 3/4 in. (required)
G Hydraulic inlet, 3/8 npt
H *Supply line shutoff valve
J *Pressure gauge
K *Pressure reducing valve (required in systems over 1500
psi [10 MPa, 102 bar])
L *Flow control valve (required in systems over 3 gpm [11
lpm])
M Hydraulic supply line (use only Graco hydraulic power
supply)
N Material supply
P Ground wire (required)
R Wall mounting bracket, P/N 236778 (see manual 308394)
S Thermal Relief Kit (required)
Hydraulic System
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 the hydraulic lines with air, flush thoroughly
with solvent, and then blow out with air again before
connecting 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 recommendations
on reservoir and filter cleaning, and periodic changes in
hydraulic fluid.
FIG. 2: Typical Installation
D
H
M
F
J
E
G
K
L
R
N
C
B
S
A
P

Installation
308390N 7
Hydraulic Power Supply
The hydraulic power supply system must have a pres-
sure reducing valve and a pressure-compensated flow
control. A flow control valve (L) is required to limit the
incoming flow to the reciprocator to a maximum of 3
gpm (11 lpm).
A supply line shutoff valve (H), pressure gauge (J), pres-
sure reducing valve (K), and flow control valve (L) are
included in the Hydraulic Fluid Control Kit, Part No.
236864, which can be ordered separately.
Hydraulic Lines
Refer to FIG. 2 to locate the part mentioned below.
Shutoff Valves (F and H) are installed in the hydraulic
supply and return lines.
Drain Line. Remove the plug (A) from the pump adapter
and install a 1/8-27 npt(f) tube fitting and weep tube,
ending in a waste container. Monitor the weepage of
hydraulic fluid. If it seems excessive or increases sud-
denly, the reciprocator/pump seals may need to be
changed. See page 12.
Hoses. Use a minimum 1/2 in. supply line (M) and mini-
mum 3/4 in. return line (D) on the reciprocator. Contact
your Graco representative for details of line sizing.
A pressure reducing valve (K) circulates excess
hydraulic fluid pressure back to the hydraulic power sup-
ply. Install this valve in the hydraulic supply line (M) with
a drain hose teed into the hydraulic return line (D). LImit
supply pressure to a maximum of 1500 psi (10 MPa,
102 bar).
A fluid-filled pressure gauge (L), Part No. 112567,
monitors hydraulic pressure to the reciprocator during
startup. Use the gauge for initial adjustment of the recip-
rocator. It can be removed after adjustment is made.
NOTE: A supply line shutoff valve (H), pressure gauge
(J), pressure reducing valve (K), and flow control valve
(L) are included in the Hydraulic Fluid Control Kit, Part
No. 236864, which can be ordered separately.
Limit Fluid Flow to Reciprocator
To reduce risk of over pressurizing 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).

Operation
8308390N
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Shut off the hydraulic power supply.
2. Close the supply line shutoff valve (H).
3. Open the dispensing valve to relieve pressure.
4. Open the pump outlet drain valve (C) and have a
container ready to catch the drainage.
5. Close the return line shutoff valve (F).
6. Leave the drain valve open until you are ready to
dispense again.
NOTE: If you suspect that the nozzle or hose is com-
pletely 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 Starting the Pump
1. Check all 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 Technical
Data, page 20. Flush until clean solvent comes from
the outlet hose.
Starting the Pump
1. Turn on the hydraulic power supply.
2. Open the return line shutoff valve (F) and slowly
open the hydraulic supply line shutoff valve (H).
3. Adjust the flow control valve (L) 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 control
adjustment (K), increase the hydraulic inlet pressure
from 500-1500 psi (3.4-10 MPa, 34-102 bar).
Increasing the inlet pressure increases the outlet
pressure. Decreasing the inlet pressure decreases
the outlet pressure.
5. Always use the lowest pressure possible to obtain
the desired results. This reduces pump wear.
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 spraying and before
cleaning, checking, or servicing the equipment.
Be sure you always shut off the hydraulic supply line
shutoff valve (H) before you close the return shutoff
valve (F). This is to prevent over pressurizing the
motor or its seals. When starting up the hydraulic
system, open the return line shutoff valve first.
NOTICE
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 sup-
ply 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.

Operation
308390N 9
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. (FIG. 3)
Shutdown
Relieve the pressure whenever shut down. See Pres-
sure Relief Procedure on page 8.
FIG. 3
SELF-SEALING FIT-
TING (16, 17, 25)
O-RING
RECIPROCATOR

Troubleshooting
10 308390N
Troubleshooting
1. Follow Pressure Relief Procedure, page 8.
2. Check all possible problems and causes before dis-
assembling gun.
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
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. Check; clear
obstructions
Reciprocator damaged. Repair, See page 12 or 17.
Pump speeds up or runs erratically Pump piston and/or intake valve
worn
Relieve pressure. Check and repair.
See page 17.
Empty supply container Refill and reprime. 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. Check and repair.
See page 17.
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
obstruction
Excessive weepage from porous
plug (A)
Worn throat seals Repair. See page 11
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
leaking persists, change o-rings