Graco Dyna-Star 236753 Bedienungsanleitung

308–390

Rev. D

Supersedes Rev. C

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 AND PUMP

1500 psi (10 MPa, 102 bar) Maximum Hydraulic Input Pressure

375 psi (2.6 MPa, 26 bar) Maximum Fluid Outlet Pressure

FOR

LUBRICA

TING FLUIDS ONL

1/4:1

TIO UNIVERSAL PUMP AND RECIPROCATOR

Model 236–753, Series C, stubby length

RECIPROCAT

OR ONL

Model 239–884, Series A

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

http://www.graco.com

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

This equipment is for professional use only

Read all instruction manuals, tags, and labels before you operate the equipment.

Use the equipment only for its intended purpose. If you are not sure, call your Graco distributor

Do not alter or modify this equipment. Use only genuine Graco parts and accessories.

Check equipment daily

. Repair or replace worn or damaged parts immediately

Do not exceed the maximum working pressure of the lowest rated component in your system.

This equipment has a

1500 psi (10 MPa, 102 bar) maximum hydraulic input pressure and

375 psi (2.6 MPa, 26 bar) maximum fluid outlet pressure.

Use fluids and solvents that are compatible with the equipment wetted parts. Refer to the

echnical Data

section of all equipment manuals. Read the fluid and solvent manufacturer

’s

warnings.

Handle hoses carefully

. Do not pull on hoses to move equipment.

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).

Do not lift pressurized equipment.

Comply with all applicable local, state, and national fire, electrical, and safety regulations.

WARNING



FLUID 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



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 couplers 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 operating 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.

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

WARNING

HALOGENATED HYDROCARBON HAZARD

Never

use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or

fluids containing such solvents in aluminum pumps. Such use could result in a serious chemical

reaction, with the possibility of explosion, which could cause death, serious injury

, and/or substantial

property damage.

Consult your fluid suppliers to ensure that the fluids used are compatible with aluminum parts.

4 308-390

MOVING

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

United States Government safety standards have been adopted under the Occupational Safety and Health Act.

ou should consult these standards––particularly the General Standards, Part 1910.

5308-390

Installation

KEY

BPorous

plug (weep tube optional)

Fluid dispenser outlet

Drain valve (required)

Hydraulic return line,

minimum 3/4” I.D. (required)

Hydraulic outlet, 3/4 npt

Return line shutof

f valve,

minimum 3/4” (required)

Hydraulic inlet, 3/8 npt

Supply line shutof

f valve

Pressure gauge

Pressure reducing valve

(required

in systems over 1500

psi

[10

MPa, 102 bar])

Flow control valve

(required in systems over 3 gpm

1 lpm])

Hydraulic supply line (use only

graco hydraulic power supply)

Material supply

Ground wire (required)

all mounting bracket 236–778

(see manual 308–394)

Typical

Installation – Suction Feed System

Fig. 1 03516

*Included

in Hydraulic Fluid Control Kit 236–864, which can be ordered separately

Although

the installation shown in Fig. 1 is only a guide

for selecting and installing system components and

accessories, some of the equipment is required, as

noted in the key. For assistance in designing a system

to suit your needs, contact your Graco distributor

Mount the pump to suit the type of installation planned.

WARNING

Mount the pump securely so that it cannot move

around during operation. Failure to do so could

result in personal injury or equipment damage.

Maximum W

orking Pressure of Accessories

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, 102 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

Hose Kit, Part No. 236–054

A suction tube kit is available for siphoning from

55-gallon containers.

Intake T

ube

(not shown)

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, Part No. 203–688

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, Part No. 222–01

A ground wire is required.

Pump Outlet Drain V

alve

, Part No. 210–658

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

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.

CAUTION

Hydraulic Power Supply

Limit Fluid Flow to Reciprocator

o reduce the risk of overpressurizing 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 (1

1 lpm) and 1500 psi (10 MPa, 102 bar). See

the description below

WARNING

The hydraulic power supply system must have a

pressure reducing valve and a pressure-compensated

flow control. A flow control valve (N) is required to limit

the incoming flow to the reciprocator to a

maximum of

3 gpm (1

1 lpm)

NOTE:

A supply line shut-of

f valve (K), pressure

gauge (L), pressure reducing valve (M), and flow

control valve (N) are included in the Hydraulic Fluid

Control Kit 236–864, which can be ordered separately

PTFE

7308-390

Installation

Hydraulic Lines

NOTE: Refer

to Fig. 1 to locate the parts mentioned

below.

DShut-off valves (H and K)

are installed in the

hydraulic supply and return lines. Order Part No.

108–458 for 1/2 npt(f) supply lines and 108–537 for

3/4 npt(f) return lines.

Drain Line. Remove the plug (B) 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 suddenly

, the reciprocator/pump seals

may need to be changed. See page 1

DHoses.

Use a minimum 1/2” supply line (P) and

minimum 3/4” return line (F) on the reciprocator

Contact your Graco representative for details of line

sizing.

A pressure reducing valve (M)

circulates excess

hydraulic fluid pressure back to the hydraulic power

supply

. Install this valve in the hydraulic supply line

(P) with a drain hose teed into the hydraulic return

line (F). Limit supply pressure to a maximum of

1500 psi (10 MPa, 102 bar).

A fluid-filled pressure gauge (L), Part No.

112–567,

monitors hydraulic pressure to the

reciprocator during startup. Use the gauge for

initial adjustment of the reciprocator

. It can be

removed after adjustment is made.

NOTE:

A supply line shut-of

f valve (K), pressure

gauge (L), pressure reducing valve (M), and flow

control valve (N) are included in the Hydraulic Fluid

Control Kit 236–864, which can be ordered separately

Grounding

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.

Pump:

Use ground wire and clamp as shown in

Fig. 2. T

o order a Grounding Wire and Clamp Kit,

order Part No. 222–01

Hydraulic Hoses and Fluid Outlet Hoses:

Use only

electrically conductive hoses.

Hydraulic Power Supply:

Follow manufacturer

’s

recommendations.

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.

Fig. 2

ZX W

03517

 

Operation

Pressure Relief Procedure

INJECTION

HAZARD

The system pressure must be manually

relieved to prevent the system from

starting or dispensing 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

Are instructed to relieve the pressure

Check or service any of the system equipment

Install or clean the nozzle

WARNING

Shut of

f the hydraulic power supply

Close the supply line shut-of

f valve (K in Fig. 1).

Open the dispensing valve to relieve pressure.

Open the pump outlet drain valve, and have a

container ready to catch the drainage.

Close the return line shut-of

f valve (H).

NOTE:

Leave the drain valve open until you are ready

to dispense 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, then clear the

obstruction.

Be sure you

always

shut of

f the hydraulic supply

line shutof

f valve (K) before you close the return

line shutof

f valve (H). This is to prevent overpres

surizing the motor or its seals. When starting up

the hydraulic system, open the return line shutof

valve first.

WARNING

Before

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.

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

Check the hydraulic fluid level in the hydraulic

power supply

before each use

and add fluid as

necessary to fill the lines.

Flush the pump before using it for the first time

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

echnical Data

on page 23. Flush until clean

solvent comes from the outlet hose.



Operation

Starting the Pump

Maximum

orking Pressures

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, 102 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, 102 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 (1.8 Mpa, 18 bar).

WARNING

1. T

urn on the hydraulic power supply

Open the return line shutof

f valve (H), and slowly

open the hydraulic supply line shutoff valve (K).

Adjust the flow control valve (N) to limit the

hydraulic flow to no more than 3 gpm (1

1 lpm),

which is approximately 60 cycles per minute.

NOTE:

If Graco Part No. 236–864 hydraulic fluid

control is used, no adjustment is necessary

By adjusting the pressure reducing valve control

adjustment (M), increase the hydraulic inlet

pressure from 500 to 1500 psi (3.4 to 10 MPa, 34

to 102 bar). Increasing the inlet pressure

increases the outlet pressure. Decreasing the inlet

pressure decreases the outlet pressure.

Always use the lowest pressure possible to obtain

the desired results. This reduces pump wear

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.

o prevent the pump from running dry

, use a low-

level cutoff valve.

CAUTION

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

Relieve

the pressure

whenever you shut down.

WARNING

o reduce the risk of serious injury whenever you

are instructed to relieve pressure, always follow the

Pressure Relief Procedure

on page 8.

10 308-390

Troubleshooting

WARNING

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 lpm) 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

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).

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.

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