Graco Dyna-Star 239882 Bedienungsanleitung

Instructions

Dyna-Star™Hydraulic

Reciprocator and Pump 308155U

For lubricating fluids only. For professional use only.

1:1 Ratio Universal Pump and Reciprocator

Model 239882, Series A,

Reciprocator Only

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

Pressure

1500 psi (10 MPa, 102 bar) Maximum Fluid Outlet

Pressure

Model 224741, Series C,

Stubby Length

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

Pressure

1500 psi (10 MPa, 102 bar) Maximum Fluid Outlet Pres-

sure

Model 224742, Series C,

55 Gallon Length

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

Pressure

1500 psi (10 MPa, 102 bar) Maximum Fluid Outlet Pres-

sure

Model 237653, Series B,

Stainless Steel Stubby Length Pump

1000 psi (7 MPa, 70 bar) Maximum Hydraulic Input

Pressure

1000 psi (7 MPa, 70 bar) Maximum Fluid Outlet Pres-

sure

Important Safety Instructions

Read all warnings and instructions in this

manual. Save these instructions.

Warnings

2308155U

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

308155U 3

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.

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

4308155U

Installation

Grounding

Pump: Use ground wire and clamp as shown in FIG. 1.

Hydraulic hose and fluid outlet hoses: use only elec-

trically 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 ground the pump: Remove the ground screw (Z)

and insert through the eye of the ring terminal at 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. (FIG. 1)

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

Installation

308155U 5

Key:

A Suction hose

B Weep tube

C Fluid outlet line (to gun)

D Drain valve (required)

E Ground wire

F Hydraulic return line, minimum 3/4” I.D. (required)

G Hydraulic outlet, 1/2 npt

H Return line shut-off valve, minimum 3/4” (required)

J Hydraulic inlet, 1/2 npt

K Tee, 3/4 npt

L *Supply line shut-off valve

M *Pressure gauge

N *Pressure reducing valve (required in systems over 1500

psi [10.2 MPa, 102 bar])

P Accumulator

R *Flow control valve (required in systems over 3 gpm [11

lpm])

S Hydraulic supply line

T Check valve

U Variable volume pressure compensated pump

V Hydraulic power supply

W Drain line, accumulator

X Low-level cut-off valve

Y Thermal Relief Kit (required)

* Included in Hydraulic Fluid Control Kit, 236864, which can be ordered separately.

Although the installation shown in FIG. 2 is only a guide for selecting and installing system components and accesso-

ries, some equipment is required, as noted in the key. For assistance in designing a system to suit your needs, con-

tact your Graco distributor.

Mount the pump to suit the type of installation planned.

FIG. 2: Typical Installation

EFGH

JKLMN

Installation

6308155U

Pump Accessories

• A suction hose kit (A) is available for siphoning from

55 gallon containers.

• Intake tube (not shown). To install, apply PTFE tape

to the female threads at the top of the tube. Screw

the tube tightly into the intake housing of the stubby

pump.

• Low-level cut-off valve (X) closes the pump intake

when the fluid level is low, causing the pump to stall

to avoid running dry. To install, screw the valve into

the bottom of the pump intake tube or the suction

tube.

• A pump outlet drain valve (D) is installed close to

the pump fluid outlet to help relieve fluid pressure in

the pump when the pump is shut off.

• Thermal relief kit (Y). Install at the pump fluid outlet.

Hydraulic System

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 solvent, and blow out with air

again before you connect the lines to the reciprocator.

Always plug the hydraulic inlets, outlets, and lines when

you disconnect them for any reason to avoid introducing

dirt and other contaminants into the system.

Carefully follow the manufacturer’s recommendations

on cleaning the reservoir and filter and periodically

changing the hydraulic fluid.

Hydraulic Power Supply

The hydraulic power supply system (V) must have a

pressure reducing valve and a pressure-compensated

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

the incoming flow to the reciprocator to a maximum of 3

gpm (11 lpm).

NOTE: A supply line shut-off valve (L), pressure gauge

(M), pressure reducing valve (N), and a flow control

valve (R), are including in the Hydraulic Fluid Control

Kit, 236864, which can be ordered separately.

Mount the pump securely so that it cannot move

around during operation. Failure to do so could result

in personal injury or equipment damage.

NOTICE

Pump Outlet Drain Valve

A pump outlet drain valve (D) is required in your

system. This valve helps relieve pressure in the

displacement pump and hose when the system is

shut down and if the outlet hose gets clogged. Install

the valve close to the pump outlet.

Limit Fluid Flow to Reciprocator

To reduce the 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 (10.2 MPa, 102 bar).

Installation

308155U 7

Hydraulic Lines

Refer to FIG. 2 for the parts mentioned in the following

instructions.

• Shut off valves (H and L): Installed in the hydraulic

supply and return lines.

• Drain Line (W): Remove the plug (59) from the

pump adapter, and install a 1/8-27 npt(f) tube fitting

and weep tube (B), ending in a waste container.

Monitor the weepage of hydraulic fluid. If it seems

excessive or increases suddenly, the reciproca-

tor/pump seals may need to be changed. (FIG. 3)

• Hose: Use a minimum 1/2” supply line (R) and mini-

mum 3/4” return line (F) on the reciprocator. Contact

your Graco representative for details of line sizing.

• Pressure reducing valve (N): Circulates excess

hydraulic fluid pressure back to the hydraulic power

supply. Install this valve (N) in the hydraulic supply

line with a drain hose (W) teed into the hydraulic

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

of 1500 psi (10.2 MPa, 102 bar).

• Accumulator (P): Reduces the hammering effect

caused by the motor when it reverses direction.

• Fluid-filled pressure gauge (M): Monitors hydraulic

pressure to the reciprocator during start up. Use the

gauge for initial adjustment of the reciprocator. It

can be removed after adjustment is made.

FIG. 3

Operation

8308155U

Operation

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever

you see this symbol.

1. Shut off the hydraulic power.

2. Close the supply line shut-off valve (L, FIG. 2).

3. Open the dispensing valve to relieve pressure.

4. Open the pump outlet drain valve and have a con-

tainer ready to catch the drainage.

5. Close the return line shut-off valve (H).

NOTE: Leave the drain valve open until you ar 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.

Before Starting the Pump

1. Check the hydraulic fluid level in the hydraulic

power supply before each use, and add fluid as nec-

essary to fill the lines.

2. Flush the pump before you use it for the first time to

remove the light oil that was left in after factory test-

ing 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 25. Flush until clean solvent comes from

the outlet hose.

To Start the Pump

1. Turn on the hydraulic power supply.

2. Open the return line shut-off valve (H), and slowly

open the hydraulic supply shut-off valve (L).

3. Adjust the flow control valve (R) to limit the hydraulic

flow to no more than 3 gpm (11 lpm), which is

approximately 60 cycles per minutes.

NOTE: If Graco Part No. 236864 hydraulic fluid control

is used, no adjustment is necessary.

4. By adjusting the pressure reducing valve (N), adjust

the hydraulic inlet pressure from 50 to 1500 psi

(0.34 to 10.2 MPa, 3.4 to 102 bar) for models

239882, 224741, and 224742. Increasing the inlet

pressure increases the outlet pressure. Decreasing

the inlet pressure decreases the outlet pressure.

NOTE: For model 237653, adjust the hydraulic inlet

pressure from 50 to 1000 psi (0.34 to 7 MPa, 3.4 to 7

bar).

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.

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 cut off valve (X).

Operation

308155U 9

Shutdown

Relieve the pressure whenever you shut down. See

Pressure Relieve Procedure on page 8.

If the Pump Leaks at the Fluid

Fittings

Models 239882, 224741, and 224742: Tighten the fit-

tings (1, 5, 58) which are self sealing and have replace-

able o-rings. If leaking persists, change the o-rings. (FIG.

Model 237653: Tighten fittings (B or K). These fittings

are self sealing and have replaceable o-rings. If leaking

persists, change the o-rings. (FIG. 5)

FIG. 4

self-sealing

fitting (1,5,58)

o-ring

(1a,5a,58a)

reciprocator

FIG. 5

self-sealing

fitting (B or K)

reciprocator

o-ring

Troubleshooting

10 308155U

Troubleshooting

1. Follow Pressure Relief Procedure, page 8, before

checking or repairing gun.

2. Check all possible problems and causes before dis-

assembling gun.

Problem Cause Solution

Pump won’t run

Closed dispense valve Pump only runs with valve open.

Pressure too low Increase supply pressure using a

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

obstruction.

Reciprocator damaged Repair. See page 11.

Pump speeds up or runs erratically

Pump piston and/or intake valve is

worn

Relieve pressure. Check and repair.

See page 11

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 11.

Pump runs but output low on both

strokes

Insufficient hydraulic fluid supply Check hydraulic supply. Adjust to

maximum 3 gpm (11 lpm) flow.

Pressure too low Increase supply pressure using a

pressure adjusting valve.

Clogged fluid outlet line, intake

valve, dispense valve, suction line

Relive pressure. Check; clear

obstructions.

Excessive weepage from weep tube

(B) Worn throat packings Repair. See page 11.

Hydraulic oil leaks from fittings in

the upper or lower reciprocator

blocks (31, 32)

Fittings (1, 5, 58) are loose, or their

o-rings are worn or damaged

Tighten the self sealing fittings. If

leaking persists, change the o-rings.

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