Graco Dyna-Star 77X100 Gebrauchs- und Pflegehandbuch

Instructions, Repair and Parts

Dyna-Star®HP

Pump System 332540B

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

system. For automatic lubrication systems only.

Not approved for use in explosive atmospheres or hazardous locations.

Graco Tank Injector Lubrication Systems

3500 psi (24.1 MPa, 241 bar) Maximum Working

Pressure

Models

All models include Tube-in-Tube design, vent valve,

cover and tank.

Important Safety Instructions

Read all warnings and instructions in this

manual and the Dyna-Star HP and HF

Pump instruction manual. Save all

instructions.

System

Models

Size Dip

Stick

35/60

Pound

90/120

Pound

77X100 X X

77X101 X X

Warnings

2332540B

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.

WARNINGWARNINGWARNING

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

332540B 3

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.

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

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.

• 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

4332540B

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

332540B 5

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 outlet connection

B Pump

C Ignition switch*

D High-pressure lubricant supply lines*

E Injector banks*

F Lubrication controller*

G Fill port

HOverflowport

J Breather

K Reservoir

L Vent Valve

M Motor

N Dip Stick

*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

Installation

6332540B

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 and no

more lubricant or air is leaking from fitting as shown in

FIG. 2.

•Read and follow instructions supplied with each sys-

tem component.

•Reference letters used in the following Installation

instructions, refer to Typical Installation Key, page 5.

Wiring

Grounding

System Configuration and Wiring

NOTE: Cable wiring harness kits are available from

Graco. See Parts page 11 for a complete list of available

kits.

Fuses

Reservoir Installation

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. 2

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 sys-

tem, be sure you know the maximum working pres-

sure 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.

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 with-

out a fuse installed.

• A fuse of the correct voltage and amperage must

be installed in line with the power entry to the

system. Graco recommends using 35A fuses.

HEAVY EQUIPMENT HAZARD

Equipment is heavy. To avoid injury:

• Be sure unit is securely mounted before operation.

• Do not lift pressurized equipment.

• 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, in the pump

instruction manual for pump weight.

Operation

332540B 7

1. Mount Reservoir on sturdy, flat surface. Note loca-

tion of Fill Port (G) and Lubricant Outlet Connection

(A) for easy access once installed.

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

the Lubricant Outlet Connection (A).

3. Ground system (see Grounding). Mount reservoir

to grounded chassis member.

Pump Installation

Pump installation instructions are provided in the

Dyna-Star HP or HF Pump instruction manual 332514

provided with your system.

Vent Valve Kit

The vent valve is used to reduce system pressure and

allow the injector to reset. When energized, grease is

pumped out through the outlet port (marked 0) on the

vent valve. When de-energized, it vents pressure inter-

nally to tank.

Refer to the Dyna-Star HP or HF Vent Valve Kit manual

332515 for installation and operation instructions.

Operation

•Read and follow instructions supplied with each sys-

tem component.

•Reference letters used in the following Installation

instructions, refer to Typical Installation Key, page 5.

Start-up

Priming

1. After reservoir/tank is completely filled, remove high

pressure lubricant supply line (D) from the outlet.

2. Connect power to pump.

3. Start pump and run pump until all air has been

expelled and fluid flow is continuous.

4. Reconnect the high pressure lubricant supply line

(D) to outlet.

Do not insert finger into the overflow port while

filling a reservoir equipped with a follow plate. Injury

or amputation could result.

Operation

8332540B

Filling Reservoir

1. Connect lubricant supply hose from remote filling

station pump to Fill Port (G).

2. Remove plug from Overflow Port (H).

3. Slowly turn on supply lubricant until level of lubricant

reaches Overflow Port (H).

NOTE: For systems with a follower plate, fill unit until the

follower plate reaches the Overflow Port (H).

4. Disconnect lubricants supply hose from Fill Port (G).

5. Plug Fill Port (G) and Overflow Port (H).

Shutdown

For normal system shut down, disconnect power by

turning off the ignition switch (C).

NOTICE

To prevent damage to the unit:

• Check Breather vent (J) for proper operation

before filling reservoir.

• Open Overflow Port (H) before filling for visual

inspection of lubricant level.

• Do not fill beyond Overflow Port (H).

• Do not use Overflow Port (H) to fill reservoir.

NOTICE

Never allow pump to run dry of the fluid being pumped.

Running a pump dry can damage the pump.

Parts List

332540B 9

Parts List

Model 77X100: Dyna-Star Pump, 60#, Dip Stick, Reservoir, Cover, Vent Valve

Model 77X101: Dyna-Star Pump, 90#, Dip Stick, Reservoir, Cover, Vent Valve

Cable Harness Kits

Ref.

No. Part No. Description Qty

1 77X011 KIT, pump and vent valve,

includes 1a and 1b, Dyna-Star

60#, models 77X100, see instruc-

tion manual 332514

77X012 KIT, pump and vent valve,

includes 1a and 1b, Dyna-Star

90#, models 77X101, see instruc-

tion manual 332514

1a PUMP 1

1b VENT VALVE, see instruction

manual 332519

3 77X535 KIT, reservoir, 60# grease,

models 77X100

77X536 KIT, reservoir, 90# grease,

models 77X101

3a 100737 . PLUG, pipe 2

3b 108126 . TEE, pipe 1

3c 110996 . NUT, flanged, hex 8

3d 111800 . SCREW, cap, flange head 4

3e 115254 . BREATHER 1

3f 194868 . GASKET, cover 1

3g 15R105 . PAIL, reservoir, 60#, included in

kit 77X535

194907 . PAIL, reservoir, 90#, included in

kit 77X536

3h 16V394 . COVER, reservoir 1

3i 104663 . PLUG, pipe (not shown) 1

3j 109114 . SCREW, cap 4

3k 15M442 . GASKET, pump 1

3l 104572 . WASHER, lock, spring 4

3m 16V396 . SEAL 1

3n 16V395 . COVER 1

4 77X531 KIT, dip stick, 60#, grease, see

instruction manual 332515

77X530 KIT, dip stick, 90#, grease, see

instruction manual 332515

Part No. Description

77X527 KIT, cable harness, receptacle (female)

77X528 KIT, cable harness, plug (male)

77X529 KIT, cable, harness, receptacle and vent valve

Parts Drawing

10 332540B

Parts Drawing

Model 77X100: Dyna-Star Pump, 60#, Dip Stick, Reservoir, Vent Valve

Model 77X101: Dyna-Star Pump, 90#, Dip Stick, Reservoir, Vent Valve

1b 4

3m/3n

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