Graco Dyna-Star HP 77X100 Use and care manual

332540K
EN
Instructions, Repair and Parts
Dyna-Star HP Pump
System
Provides lubricant flow and pressure to operate a single-line parallel automatic lubrication
system. For automatic lubrication systems only. For professional use only.
Not approved for use in explosive atmospheres or hazardous (classified) locations.
Models
3500 psi (24.1 MPa, 241 bar) Maximum Working Pressure
See page 3 for model information and approvals.
Related Manuals
Find English manuals and any available translations at
www.graco.com.
Important Safety Instructions
Read all warnings and instructions in this
manual and the Dyna-Star HP and HF Pump
before using the equipment. Be familiar with the
proper control and usage of the equipment.
Save these instructions.
English
Manual
Number
Description
332514 Dyna-Star HP and HF Pump
332515 Dyna-Star HP or HF Pump Low Level Indicator
Kit; Dip Stick Kit
332518 Dyna-Star HP and HF Pump Auto-Fill Shut Off Kit
332519 Dyna-Star HP Vent Valve Kit
Models 77X100 and 77X101 shown

Contents
2 332540K
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Injector System . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Series Progressive System . . . . . . . . . . . . . . . . . 8
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
System Configuration and Wiring . . . . . . . . . . . . 9
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Reservoir Installation . . . . . . . . . . . . . . . . . . . . . . 9
Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Vent Valve Kit . . . . . . . . . . . . . . . . . . . . . . . . 9
Auto-Fill Shut Off . . . . . . . . . . . . . . . . . . . . . . 9
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 10
Start Up and Adjustment . . . . . . . . . . . . . . . . . . 10
Prime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fill the Reservoir . . . . . . . . . . . . . . . . . . . . . 11
Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Recycling and Disposal . . . . . . . . . . . . . . . . . . . . . 12
End of Product Life . . . . . . . . . . . . . . . . . . . . . . 12
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Model 77X100: Dyna-Star Pump, 60#, Dip Stick,
Reservoir, Cover, Vent Valve . . . . . . . . . . . . 13
Model 77X101: Dyna-Star Pump, 90#, Dip
Stick, Reservoir, Cover, Vent Valve . . . . . . . 13
Model 77X300: Dyna-Star Pump, 60#, Dip Stick,
Reservoir, Cover . . . . . . . . . . . . . . . . . . . . . 13
Model 77X301: Dyna-Star Pump, 90#, Dip Stick,
Reservoir, Cover . . . . . . . . . . . . . . . . . . . . . 13
Model 77X102: Dyna-Star Pump, 60#, Auto-Fill
Shut Off, Reservoir, Cover, Vent Valve . . . . 14
Model 77X103: Dyna-Star Pump, 90#, Auto-Fill
Shut Off, Reservoir, Cover, Vent Valve . . . . 14
Model 77X104: Dyna-Star Pump, 60#, Low Level,
Reservoir, Cover, Vent Valve . . . . . . . . . . . . 15
Model 77X105: Dyna-Star Pump, 90#, Low
Level, Reservoir, Cover, Vent Valve . . . . . . 15
Model 77X304: Dyna-Star Pump, 60#, Low
Level, Reservoir, Cover . . . . . . . . . . . . . . . . 15
Model 77X305: Dyna-Star Pump, 90#, Low
Level, Reservoir, Cover . . . . . . . . . . . . . . . . 15
Model 133846: Dyna-Star Pump, 60#, Low
Level, Follower Plate, Reservoir, Cover, Vent
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cable Harness Kits (all models) . . . . . . . . . . 15
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Technical Specifications . . . . . . . . . . . . . . . . . . . . 17
California Proposition 65 . . . . . . . . . . . . . . . . . . . . 17
Graco Standard Warranty. . . . . . . . . . . . . . . . . . . . 18

Models
332540K 3
Models
All models include Tube-in-Tube design, vent valve, cover, and tank.
System
Models
Size Maximum
Working
Pressure❊
Dip
Stick
Low
Level
Follower
Plate*
Auto-Fill
Shut Off Approvals
35/60
Pound
90/120
Pound
77X100 X 3500 psi
(24.1 MPa.
241 bar)
X
77X101 X X
77X102 X X
77X103 X X
77X104 X X X
77X105 X X X
77X300 X X
77X301 X X
77X304 X X X
77X305 X X X
133846 X X X
*Can only be used with Low Level models
❊The Dyna-Star HP Pump is rated for a maximum working pressure of 5000 psi (34.4 MPa, 344 bar). However, when a vent valve
is installed on the HP Pump, the maximum working pressure is reduced to 3500 psi (24.1 MPa, 241 bar).

Safety Symbols
4 332540K
Safety Symbols
The following safety symbols appear throughout this manual and on warning labels. Read the table below to
understand what each symbol means.
Symbol Meaning
Burn Hazard
Equipment Misuse Hazard
Fire and Explosion Hazard
Moving Parts Hazard
Skin Injection Hazard
Skin Injection Hazard
Splash Hazard
Do Not Place Hands or Other Body
Parts Near Fluid Outlet
Do Not Stop Leaks with Hand,
Body, Glove or Rag
Follow Pressure Relief Procedure
Ground Equipment
Read Manual
Wear Personal Protective
Equipment
Symbol Meaning
Safety Alert Symbol
This symbol indicates: Attention! Become Alert! Look for this symbol throughout the
manual to indicate important safety messages.

General Warnings
332540K 5
General Warnings
The following warnings apply throughout this manual. Read, understand, and follow the warnings before using this
equipment. Failure to follow these warnings can result in serious injury.
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.
• Ground all equipment in the work area.
• 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.
• 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.
PRESSURIZED EQUIPMENT HAZARD
Over-pressurization can result in equipment rupture and serious injury.
• A pressure relief valve is required at each pump outlet.
• Follow the Pressure Relief Procedure win this manual before servicing.

General Warnings
6 332540K
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 Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical
Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For
complete information about your material, request Safety Data Sheets (SDSs) 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.
• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the
Pressure Relief Procedure and disconnect all power sources.
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, including
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 manufacturer.
WARNING

Typical Installation
332540K 7
Typical Installation
Injector System
The installation shown in FIG. 1 is only a guide for selecting and installing system components and accessories.
Contact your Graco distributor for assistance in designing a system.
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 (not used with Auto-Fill Shut Off)
H Overflow Port (not used with Auto-Fill Shut Off)
J Breather Vent
K Reservoir
L Vent Valve
M Motor
N Fluid Overflow Container
P Pump - Remote Filling Station
R Reservoir - Remote Filling Station
S Auto-Fill Shut Off
*User Supplied
FIG. 1

Typical Installation
8 332540K
Series Progressive System
The installation shown in FIG. 2 is only a guide for selecting and installing system components and accessories.
Contact your Graco distributor for assistance in designing a system.
Key:
A Lubricant Outlet Connection†
B Pump†
C Ignition Switch*
D High-Pressure Lubricant Supply Lines*
F Lubrication Controller*
G Fill Port (not used with Auto-Fill Shut Off)
H Overflow Port (not used with Auto-Fill Shut Off)
J Breather Vent
K Reservoir
M Motor
T Primary Divider Valve*
U Secondary Divider Valve*
V Bearing
* User Supplied
†The pump outlet requires modification to convert an Injector
based system to Series Progressive system. Graco offers
Dyna Star HF and HP Outlet Adapter Kits 77X543 rated 4000
psi (27.58 MPa, 275.8 bar) and 77X544 rated 5000 psi (34.47
MPa, 344.7 bar). Contact Graco Customer Service or your
local Graco distributor to identify the correct kit for the
installation location.
FIG. 2

Installation
332540K 9
Installation
The reference letters in the following instructions refer
to Typical Installation, page 7.
Grounding
System Configuration and
Wiring
NOTE: Cable wiring harness kits are available from
Graco. See Cable Harness Kits (all models), page 15,
for a complete list of available kits.
Fuses
Reservoir Installation
Reservoir
1. Install the reservoir in a location that adequately
supports the weight of the reservoir when filled with
lubricant and also provides easy operator access to
the fill port (G) and lubricant outlet connection (A).
2. Connect the high-pressure lubricant supply line (D)
to the lubricant outlet connection (A).
3. Ground the system, see Grounding, page 9. Mount
the reservoir to the grounded chassis member.
Pump
Follow the pump installation instructions provided in
the Dyna-Star HP and HF Pump manual, see Related
Manuals, page 1, provided with the system.
Vent Valve Kit
The vent valve reduces system pressure and allows the
injector to reset. When energized, grease is pumped
through the outlet port (marked 0) on the vent valve;
when de-energized, it vents pressure internally to the
tank.
For installation and operation instructions, see the
Dyna-Star HP Vent V.alve kit manual, see Related
Manuals, page 1.
Auto-Fill Shut Off
The auto-fill shut off refills the grease reservoir instead
of using the fill port (G). When the grease level in the
tank is full, the auto-fill shut off automatically ends the
filling operation. For installation and operation
instructions, see the Dyna-Star HP and HF Pump
Auto-Fill Shut Off Kit manual, see Related Manuals,
page 1.
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 system.
The recommended fuses are 35A.
Mount the equipment securely so that it cannot move
around during operation. Failure to do so could result
in injury or equipment damage.

Operation
10 332540K
Operation
The reference letters in the following instructions refer
to Typical Installation, page 7.
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
To relieve pressure in the system, use two wrenches
working in opposite directions on the pump outlet
fitting to slowly loosen the fitting only until no more
lubricant or air is leading from the fitting (FIG. 3).
Start Up and Adjustment
Prime
1. After the reservoir is completely filled, remove the
high-pressure lubricant supply line (D) from the
outlet.
2. Connect the power to the pump.
3. Start and run the pump until all of the air has been
expelled and the fluid flow is continuous.
4. Reconnect the high-pressure lubricant supply line
(D) to the outlet.
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.
Do not lift pressurized equipment.
FIG. 3
COMPONENT RUPTURE HAZARD
The maximum working pressure of each component
in the system may not be the same. To reduce the
risk of over-pressurizing 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 com-
ponent in the system. Over-pressurizing any compo-
nent can result in rupture, fire, explosion, property
damage and serious injury.
Regulate input pressure to the remote fill pump so
that no fluid line, component or accessory is over
pressurized.
Do not insert fingers into the overflow port while
filling a reservoir equipped with a follower plate.
Injury or amputation could result.