Graco Dynastar 243159 Operation manual

309098F
ENG
First choice when
quality counts.t
Part No. 243159
INSTRUCTIONS–PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
For Automatic Lubrication Systems Only
Provides lubricant flow and pressure to operate a single line, parallel, automatic
lubrication system and vents the system to reset the injectors.
5:1 DynastarrPump Module
Part No. 243159, Series C
Part No. 243502 (35# Custom Tank Installation)
Part No. 243503 (120# Custom Tank Installation)
Part No. 243504 (400# Custom Tank Installation)
3500 psi (24 MPa, 240 bar) Maximum Lubricant Outlet Pressure
3500 psi (24 MPa, 240 bar) Maximum Hydraulic Fluid Input Pressure
Hydraulic Vent Valve Kit Part No. 243170
Hydraulic Control Module Kit Part No. 243501
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1999, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001

2 309098
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before you operate this equipment.
DUse the equipment only for its intended purpose. If you are not sure, call your Graco distributor.
DDo not alter or modify this equipment. Use only Graco approved repair parts.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure of the lowest rated component in your system.
DUse fluids and solvents that are compatible with the equipment wetted parts. Refer to the
Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s
warnings.
DHandle hoses carefully. Do not pull on hoses to move equipment.
DRoute 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).
DDo not lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.
DBe sure breather is not plugged before filling reservoir.
DBe sure unit is securely mounted before operation.
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.
DGround the equipment and the object being dispensed to. See Grounding on page 5.
DIf there is any static sparking or you feel an electric shock while using this equipment, stop
dispensing immediately. Do not use the equipment until you identify and correct the problem.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being dispensed.
DKeep the dispensing area free of debris, including solvent, rags, and gasoline.
DDo not smoke in the dispensing area.

3309098
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.
DKnow the specific hazards of the fluid you are using.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
DAlways wear protective eyewear, gloves, clothing and respirator as recommended by the fluid
and solvent manufacturer.
MOVING PARTS HAZARD
Moving parts, such as the air motor piston, can pinch or amputate your fingers.
DDo not insert fingers in overflow port when filling reservoir.
DKeep clear of all moving parts when you start or operate the pump.
DBefore you service this equipment, follow the Pressure Relief Procedure on page 9 to prevent
the equipment from starting unexpectedly.
INJECTION HAZARD
Fluid 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.
DFluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate
surgical attention.
DDo not put your hand or fingers over the end of grease outlet.
DDo not stop or deflect leaks with your hand, body, glove or rag.
DFollow the Pressure Relief Procedure on page 9 if the injector clogs and before you clean or
service this equipment.
DTighten all fluid connections before you operate this equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do
not repair high pressure couplings; you must replace the entire hose.
DFluid hoses must have spring guards on both ends to protect them from rupture caused by kinks
or bends near the couplings.
WARNING

4 309098
Unpacking
Unpacking the Product
The Dynastarrpump module was carefully packaged
for shipment by Graco. When the package arrives,
perform the following procedure to unpack the units:
1. Inspect the shipping box carefully for shipping
damage. Contact the carrier promptly if damage is
discovered.
2. Unseal the box and inspect the contents carefully.
There should not be any damaged parts.
3. Compare the packing slip against all items in-
cluded in the box. Any shortages or other inspec-
tion problems should be reported immediately.
4. Store the box and packing materials in a safe
place for future use. Graco recommends that all
packing materials be saved in case the unit needs
to be shipped again.
Pump Module Overview
Pump Module Capabilities
The Pump Module provides lubricant flow and pres-
sure to operate a single line parallel automatic lubrica-
tion system. The module requires a hydraulic power
Supply and a timed signal from a lubrication controller.
Based on these signals, the pump module provides
lubricant flow and pressure to operate the injectors and
vents the injector system to reset the injectors.
Pump Module Operation
Pump Module Operation performs these cycles:
1. Upon receiving a signal from a 24 volt lubrication
controller, the 3–way solenoid valve (Fig. 3,
item F) opens, starting the pump (D) and closing
the vent valve (U).
2. The pumps builds pressure until the pressure
switch in the system sends a signal to the timer,
ending the cycle, or the pump stalls.
3. The timer terminates the 24 volt signal to the
3–way solenoid valve (F).
4. The 3–way solenoid valve (F) closes, stopping the
pump and opening the vent valve (U).
5. The system lubricant pressure bleeds back
through the vent valve (U) into the reservoir (P).
6. The pressure reducing valve (PRV) (item S) and
flow control valve (FCV) (item N) control the pump
output pressure and cycle rate.

5309098
Installation
Reservoir
Mount reservoir [Fig. 2, item (P)] on sturdy flat surface
with 6, 3/8 in. diameter bolts. Note location of fill port
(K), hydraulic lines, and lubricant outlet port (G) for
easy access once installed.
Hydraulic system must depressurized before
connecting high pressure hydraulic supply line.
WARNING
CAUTION
Hydraulic supply must be 10μfiltered or better and
supply 0.5 – 3.0 gpm (1.9 – 11.4 lpm) at 800 psi –
3500 psi (55 bar – 241 bar, 5.5 MPa – 24 MPa).
1. Read instruction manual 308156 (included) before
installing this product.
2. Install ball valve (Fig. 2, item AA) (user provided)
in the 3/8” hydraulic supply line ( X).
3. Connect the 3/8” hydraulic supply line (X) to the
swivel (Y).
4. Connect the 3/4” hydraulic tank line (T) to the
swivel (Z).
5. Connect the 24 VDC timer controlled signal to
the 3–way solenoid valve (F).
6. Connect supply line (G) to the lubricant swivel (C).
7. Ground system (see Grounding below). Mount
reservoir to grounded chassis member.
Grounding (for non–mobile installation)
Loosen grounding lug locknut [Fig. 1 item (A)] and
washer (B). Insert one end of a 12 ga (1.5 mm@)
minimum ground wire (C) into slot in lug (D) and
tighten locknut securely. Connect other end of wire to
true earth ground. To order a ground wire and clamp,
order part number 222011.
0720
Fig. 1
C
A
B
D
Vent Valve Kit for Custom Tank (Part
Number 243170) Installation (See Figure 3)
1. Weld the bracket (see Fig.5 ) in place per recom-
mended configuration for mounting the vent valve .
Paint the bracket if desired.
2. Connect the hydraulic control line (Fig. 3,
item A) to the control module vent valve hydraulic
control line (Fig. 4, item J).
3. Connect the high pressure lubricant line (Fig. 3,
item C) feeding the injector system to the lubricant
output (E).
4. Connect the vent line (F) to the lubricant reservoir.
Control Module Kit for Custom Tank (Part
Number 243501) Installation (See Figure 4)
1. Mount the control module on a flat, sturdy surface
per the recommended configuration (see Fig.2 )
2. Connect the hydraulic tank line (Fig. 4, item G) to
the pump hydraulic outlet port.
3. Connect the vent valve hydraulic control (J) con-
nection to the hydraulic control line (Fig. 3, item A).
4. Connect the pump high pressure hydraulic line
(Fig. 4, item H) to the pump hydraulic input port.
5. Connect the high pressure hydraulic supply to the
high pressure hydraulic supply connection (L) and
the tank lines to the hydraulic tank connection (K).
6. Connect the 3–way solenoid valve (P) to the timer.
Note: Coil should always be installed with lettering
facing out.

6 309098
Installation
Typical Installation
The installation shown in Figs. 2, 4, and 5 are only a guide for selecting and installing system components. Contact
your Graco distributor for assistance in planning a system to suit your needs.
Fig. 2
Low Reservoir
Level Switch
(Level Indicator,
optional)
Pressure Switch
For System Control
Remote Alarm Device
(Light or Horn)
(User provided)
Controller
Capabilities
KEY
AHigh pressure hydraulic lines
BHydraulic tank line
CLubricant output connection
DPump module
EIgnition switch*
F3–Way solenoid valve
GHigh-pressure lubricant supply lines*
HInjector banks*
JLubrication controller*
KFill port
LOverflow port
MBreather
NFlow control valve (FCV)
PReservoir
RGround wire (for non–mobile installation)*
SPressure reducing valve (PRV)
THydraulic tank line*
UVent valve
VVent line
WFollower plate (optional)
XHigh pressure hydraulic line*
YHigh pressure hydraulic connection
ZTank hydraulic connection
AA Ball valve*
AB Level Indicator (optional)
* User provided
D
G
H
J
E
K
L
M
P
R
U
V
W
Front Back
A
G
B
F
N
S
T
X9649B
C
Y
Z
AA
Hydraulic
Reservoir
Return
From Hydraulic
Power Supply
AB

7309098
Fig. 3
Vent Valve Installation Kit (243170)
KEY
AHydraulic control line
BVent valve
CPump output connection line
DPressure relief valve
ELubricant output
FVent line
A
9647A
B
CD
E
F
Fig. 4
Control Module Installation Kit (243501)
KEY
GPump tank line
HPump high pressure hydraulic line
JVent valve hydraulic control
KHydraulic tank connection
LHigh pressure hydraulic connection
MPressure reducing valve
NFlow control valve
P3–Way solenoid valve
RRegulated hydraulic pressure gauge
*Coil should always be installed with lettering facing out
G
9648A
H
J
K
L
N
P
M
R
*

8 309098
Installation
Fig. 5 9653A
Vent return port
1/2” npt (f)
Vent valve bracket weld locations
Pump mounting ∅.343 or
5/16–18 (4X)
Control module ∅.343 or
5/16–18 (2X)
18.0 Max
5.0 5.0
6.875
3.536
3.536

9309098
Operation
Pressure Relief Procedure
WARNING
INJECTION HAZARD
To reduce the risk of serious injury, in-
cluding fluid injection or splashing in the
eyes or on the skin, always follow the
Pressure Relief Procedure whenever you
DAre instructed to relieve the pressure
DShut off the pump
DCheck, clean, or service any of the system
equipment
DInstall or clean the dispensing devices
1. Disable hydraulic supply to pump (Fig. 2, item D)
by isolating it it from the high pressure hydraulic
supply using ball valve (AA).
2. Do one of the following:
DOpen the pressure reducing valve to reduce
trapped hydraulic pressure,
or
DCycle the timer to open the 3–way solenoid
valve to reduce trapped hydraulic pressure.
Note: Gage on control module should read zero
pressure after performing this step.
3. Disconnect power from Lubrication Controller (J).
WARNING
MOVING PARTS HAZARD
Do not insert finger into the overflow port
while filling a reservoir equipped with a
follower plate. Injury or amputation could
result.
Start-up
Prime Vent Line. The first time the reservoir is filled,
use the vent valve outlet. This removes all air from the
vent line (Fig. 2, item V).
1. Connect lubricant supply hose from remote filling
station pump unit to outlet of vent valve (U).
2. Remove plug in fill port (K) located at bottom of
reservoir.
3. Slowly turn on supply lubricant until lubricant
appears in fill port.
4. Remove lubricant supply hose from vent valve.
Fill Reservoir
1. Connect lubricant supply hose from remote filling
station pump to fill port (Fig. 2, item K).
2. Connect automatic lube system main supply
line (G) to vent valve (U) outlet.
3. Remove plug from overflow port (L).
4. Slowly turn on supply lubricant until level of lubri-
cant reaches overflow port.
Note: For systems with a follower plate, fill until the
follower plate reaches the overflow port.
Note: Refer to Automatic Lube System Design Guide-
lines Manual 309015 for instructions on priming re-
maining system lubricant lines and further operating
instructions.
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 system, be
sure you know the maximum working pressure 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.
Regulate hydraulic pressure to the pump so that no
fluid line, component, or accessory is
overpressurized.
WARNING
5. Set hydraulic pressure to pump at lowest pressure
needed [between 600 psi (41 bar, 4.1 MPa) and
1200 psi 83 bar, 8 MPa)] to get desired output
results [between 2500 psi (172 bar, 17 MPa) and
3500 psi (241 bar, 24 MPa)].
6. Set hydraulic flow rate to pump at lowest flow rate
needed to get desired results.
7. Read and follow instructions supplied with each
system component.
Note: With a primed pump and sufficient hydraulic
supply, the pump starts when the timer activates the
solenoid valve. The pump stops when the timer deacti-
vates the solenoid valve.

10 309098
Operation
Shut Down.
1. For normal system shut down, disconnect power
to lubricator controller (J) by turning off the ignition
switch, and turn off hydraulic supply by closing the
ball valve (Fig. 2, item AA).
CAUTION
Never allow the pump to run dry of the fluid being
pumped. A dry pump will quickly accelerate to a high
speed, possibly damaging pump. If your pump
accelerates quickly, or is running too fast, stop the
pump immediately and check the fluid supply.
Troubleshooting
Problem Cause Solution
System does not build sufficient
pressure
Pump malfunction
Pump turned off too soon
Solenoid malfunction
Too low or no hydraulic supply
Vent valve seal failure
Vent valve needle/seat failure
Reservoir out of grease
Broken or leaky supply/branch line
Injector failure
Pressure in tank line too high due to
restrictions in tank line or plumbing
too small
Refer to manual 308156
Increase timer “pump on” setting
Increase hydraulic flow rate to pump
Repair or replace
Turn pressure up or supply on
Replace seal
Replace needle and seat
Fill reservoir
Tighten connections and/or replace
line(s)
Repair or replace
Remove tank line restrictions
Use larger plumbing
Lubricant dispensed from pres-
sure relief valve
System pressure set too high Decrease hydraulic pressure to pump
Pump runs too fast Reservoir out of lubricant
Pump cavitation
Leak in distribution system
Fill reservoir
Install a follower plate
Repair leak
Lubricant coming out of breather Reservoir overfilled Drain lubricant until overflow stops
Pump will not start No hydraulic supply
Solenoid malfunction
No electrical supply to lubrication
controller
Lubrication controller malfunction
Pump malfunction
Verify/check hydraulic supply
Replace solenoid
Turn on electrical supply
Refer to controller manual 308950
Refer to pump manual 308156