Graco Dyna-Star 77X000 Bedienungsanleitung

332514J

Instructions

Dyna-Star®HP and

HF Pump

Provides lubricant flow and pressure to operate a single line automatic lubrication

system. For automatic lubrication systems only. For professional use only.

Not approved for use in explosive atmospheres or hazardous locations.

Models: Page 2

Important Safety Instructions

Read all warnings and instructions in this

manual. Save these instructions.

Models

2332514J

Models

Pump

Models

Tube in

Tube

Pump

Vent

Valve

Compatible Reservoirs Maximum Working Pressure

35/60

Pound

90/120

Pound

400

Pound

3500 psi

24.1 MPa, 241 bar

5000 psi

34.47 MPa, 344 bar

77X000 X X X

77X001 X X X X

77X002 X X X X

77X003 X X X X

77X011 X X X X X

77X012 X X X X X

77X013 X X X X X

77X014 X X X

77X015 X X X

77X016 X X X

Warnings

332514J 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.

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.

WARNINGWARNINGWARNING

WARNING

Warnings

4332514J

PRESSURIZED EQUIPMENT HAZARD

Over-pressurization can result in equipment rupture and serious injury.

• A pressure relief valve is required at each pump outlet.

• Follow Pressure Relief Procedure in this manual before servicing.

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

fluids containing such solvents.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material sup-

plier for compatibility.

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.

• 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.

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.

WARNINGWARNINGWARNING

WARNING

Warnings

332514J 5

BURN HAZARD

Equipment surfaces and fluid that’s 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. 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 manufacturers.

WARNINGWARNINGWARNING

WARNING

Typical Installation: Injector System

6332514J

Typical Installation: Injector System

The installation shown in below is only a guide for selecting and installing system components. Contact your Graco

distributor for assistance in planning a system to suit your needs.

Key:

A Lubricant output connection

B Pump

C Ignition switch*

D High-pressure lubricant supply lines*

E Injector banks*

F Lubrication controller*

G Fill port (for reference only; non-tube-in-tube models only)

H Overflow port (for reference only)

J Breather (for reference only)

K Reservoir / Tank

L Vent Valve (for reference only)

M Motor

*User provided

FIG. 1

FrontBack

Low Reservoir

Level Switch

(Level Indicator,

optional)

Pressure Switch

for System Control

Remote Alarm Device

(Light or Horn)

(user provided

Controller

Capabilities

Motor Control

Board

Pump Power

Pump Signal

Vent Valve

Typical Installation: Series Progressive System

332514J 7

Typical Installation: Series Progressive System

The installation shown below is only a guide for selecting and installing system components. Contact your Graco dis-

tributor for assistance in planning a system to suit your needs.

Key:

A Lubricant output connection

B Pump

C Ignition switch*

D High-pressure lubricant supply lines*

E Primary metering device*

F Lubrication controller*

G Fill port (for reference only; non-tube-in-tube models only)

H Overflow port (for reference only)

J Breather (for reference only)

K Reservoir / Tank (for reference only)

L Secondary metering device

M Motor

N Bearing

*User provided

FIG. 2

FrontBack

Low Reservoir

Level Switch

(Level Indicator,

optional)

Pressure Switch

for System Control

Remote Alarm Device

(Light or Horn)

(user provided

Controller

Capabilities

Motor Control

Board

Pump Power

Pump Signal

Installation

8332514J

Installation

Pressure Relief

Follow the Pressure Relief Procedure whenever

you see this symbol.

To relieve pressure in the system, use two wrenches

working in opposite directions on pump outlet fitting to

slowly loosen fitting only until fitting is loose; no more

lubricant or air is leaking from fitting as shown in FIG. 3.

Pump Module

Reference numbers used in the following instructions

refer to Parts, page 35. Upper case reference letters

used in the following instructions refer to Typical Instal-

lation Drawings provided on pages 6 and 7.

NOTE:

• Tank / reservoir covers and reservoirs are available

from Graco. Contact your Graco Distributor or

Graco Customer Service for assistance ordering

these parts. See Parts, page 38 for a complete list

of accessories.

• Before installing pump on tank / reservoir, use bolts

to secure tank / reservoir to it’s installation location.

• Install tank / reservoir cover on tank / reservoir.

Tighten screws to secure cover to tank / reservoir.

1. Remove pump mounting screws (a) and washers

(b) from tank / reservoir cover. Save these parts.

Gasket (c) should not be removed from the cover.

These parts will be used to install the pump to the

tank / reservoir cover for reassembly.

2. Loosen bolts (128) and remove cover (126) from

Dyna-Star pump (FIG. 5).

3. Remove protective cap (d) from pump down-tube

(208) (FIG. 6). Discard cap. You will not use it again.

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.

FIG. 3

FIG. 4: 120 Pound Cover Shown

FIG. 5

126

128

Installation

332514J 9

4. Verify gasket (c) is in place on top the reservoir

cover, laying flat and that the holes (e) in the gasket

align with the holes in the cover (FIG. 7).

5. Install pump down-tube through opening in the cen-

ter of the gasket and tank / reservoir cover and into

tank / reservoir.

6. Align holes in pump base with holes in tank / reser-

voir cover (FIG. 8). Securely fasten pump to tank /

reservoir cover using screws (a) and washers (b)

removed in Step 1, page 8.

NOTE: When the pump is correctly installed on the

Graco tank, the breather (J) will be below the control

box (115) as shown in FIG. 9.

7. Reinstall cover (126) using bolts (128). Use a

wrench to tighten bolts securely (FIG. 10).

FIG. 6

FIG. 7

HEAVY EQUIPMENT HAZARD

Lifting or moving heavy equipment incorrectly can

cause serious injury. To avoid serious injuries, such as

muscle strain or back injuries, when moving pump

always use a lifting aid secured to the pump lift ring .

See Technical Data, included in the pump instruction

manual for pump weight information.

208

FIG. 8

FIG. 9

NOTICE

To prevent damage to the unit:

• Check breather (J) vent for proper operation

before filling reservoir.

• Open overflow port (H) before filling reservoir to

visually inspect lubrication level.

• Do not fill reservoir beyond overflow port (H).

• Do not use breather vent as a port to fill

reservoir.

115

133

Wiring

10 332514J

8. Connect the timer/controller (F) (user supplied, if

used).

9. Connect High Pressure Lubricant Supply Line (D) to

the Lubricant Output Connection (0) (FIG. 11) on the

Vent Valve or Manifold.

NOTE: The High Pressure Lubricant Supply Line

(D) is disconnected from the Lubricant Output Con-

nection (0) during Priming, page 15.

Wiring

Grounding

System Configuration and Wiring

NOTE: Cable wiring harness kits are available from

Graco. See Parts page 38 for a complete list of available

kits.

Fuses

FIG. 10

FIG. 11: Lubricant Outlet Connection

126

128

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 sys-

tem. Graco recommends using 35A fuses.

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