Graco Dyna-Star 25A189 Instructions, Repair And Parts Download Page 1

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3A3005C

Instructions, Repair and Parts

Dyna-Star

Hydraulic Reciprocator and
High Pressure Pump

High Pressure Pump and Reciprocator used for dispensing grease in wire-
line applications for oil well services.

900 psi (6.2 MPa, 62.1 bar)) Maximum Hydraulic Input Pressure
10,000 psi (69 MPa, 689 bar) Maximum Fluid Outlet Pressure

Model 25A189: 120 lb Drum Length

Important Safety Instructions

Read all warnings and instructions in this manual.
Save these instructions.

Summary of Contents for Dyna-Star 25A189

Page 1: ...used for dispensing grease in wire line applications for oil well services 900 psi 6 2 MPa 62 1 bar Maximum Hydraulic Input Pressure 10 000 psi 69 MPa 689 bar Maximum Fluid Outlet Pressure Model 25A1...

Page 2: ...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 coup...

Page 3: ...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 o...

Page 4: ...wire F Hydraulic return line minimum 3 4 inch I D required G Hydraulic outlet 3 4 NPT f H Return line shut off valve minimum 3 4 inch required J Hydraulic inlet 3 4 16 JIC 37 flare L Supply line shut...

Page 5: ...ulic power sup ply Install this valve N in the hydraulic supply line with a drain hose A teed into the hydraulic return line F Limit supply pressure to a maximum 900 psi 6 2 MPa 62 1 bar Accumulator P...

Page 6: ...metal to metal con tact between the metal part of the dispense valve and the pail Use lowest possible pres sure Grounding the Pump FIG 1 To ground pump 1 Remove ground screw Z and insert through eye...

Page 7: ...pensing and before cleaning checking or servicing the equipment COMPONENT RUPTURE HAZARD Overpressurizing any component can result in seri ous injury or property damage as a result of rupture fire and...

Page 8: ...red results This reduces pump wear If the Pump Leaks at the Fluid Fittings Tighten fittings 1 5 60 which are self sealing and have replaceable o rings If leaking persists change o rings Shutdown Relie...

Page 9: ...rn Relieve pressure page 7 Check and repair Pump runs but output low on both up and down strokes Insufficient hydraulic fluid supply Check hydraulic supply Adjust to maximum 3 gpm 11 lpm flow Pressure...

Page 10: ...p 2 Relieve pressure page 7 3 Clamp reciprocator pump assembly in a brass jaw vise 4 Disconnect fluid outlet hose C Typical Installation page 4 from displacement pump 5 Slowly loosen hydraulic supply...

Page 11: ...G 5 Replacing Throat Seals NOTE Replace throat seals if fluid leaks excessively through the weep tube B page 4 This procedure can be done without disassembling entire reciprocator Disassembly 1 Reliev...

Page 12: ...m bottom of motor housing 43 and remove motor housing from bottom cylinder cap 32 6 Loosen nut 45a on both ends of fluid tube 45 FIG 9 7 Use a wrench to loosen elbow 1 and tee 60 Remove fluid tube 45...

Page 13: ...m bottom of cylinder cap 32 Reassembly Use Kit 247455 Use all new parts included in the kit 1 Install seal 16 in bottom of cylinder cap 32 in the orientation shown in FIG 13 2 Reassemble cylinder cap...

Page 14: ...ort 32b in the bottom cylinder cap 32 are in line with each other Be sure o rings 13 are in place in the top and bottom cylinder caps as shown in FIG 15 5 Install lock washers 37 and nuts 36 onto tie...

Page 15: ...sealant and Loctite Primer T or Perma Loc 115 thread sealant and Perma Bond Surface Conditioner I are required Be sure their shelf life is within the manufacturer s recommendations For Step 8 page 17...

Page 16: ...0 Grasp top of cylinder cap 31 and pull the displace ment rod 35 out of the cylinder 25 Lay assembly on its side NOTE It is not necessary to remove tie rods 38 from the bottom cylinder cap 32 11 Place...

Page 17: ...ed from trip rod 12 during the disassembly procedure apply Loctite 609 thread sealant to first two or three internal threads of yolk 9 4 Apply Primer to external threads of trip rod 12 Allow Primer 3...

Page 18: ...assembly down into tool Make sure balls 7 snap into upper set of holes C in yoke 9 and curved ends of guide clamp have engaged valve sleeve 29 groove Slide tool D back over rod 12 to remove it FIG 24...

Page 19: ...od 35 on the assembled reciprocator is exposed so the pump can be connected to it Displacement Pump Repair Disassembly Be sure you have all necessary parts on hand before you start If using a repair k...

Page 20: ...Screw the shovel rod 108 to piston 102 torque the shovel rod to the piston to 25 30 ft lb 34 41 N m 5 Install bearing 111 and seal 112 with lips facing up in pump cylinder 109 Screw retainer seal 113...

Page 21: ...thread into pump adapter 8 Use a 7 8 inch crow foot wrench on retainer seal 113 torque to 45 55 ft lb 61 75 N m FIG 27 6 Use a strap wrench to screw together shovel tube 117 and pump cylinder 109 7 Co...

Page 22: ...n Qty 102 17J113 PISTON 1 103 196185 WASHER retainer 1 104 114171 PACKING u cup 1 106 100065 BALL 2 107 25A142 ROD connecting 1 108 192540 ROD shovel 1 109 25A165 CYLINDER pump 1 110 25A167 GASKET sea...

Page 23: ...iew Using nut 113 torque the pump cylinder 109 to the extension tube 114 at 45 to 55 ft lb 61 to 75 N m 1 Torque the shovel rod 108 to the piston 102 at 25 to 30 ft lb 34 to 41 N m 3 Torque the piston...

Page 24: ...18 114231 LOCKNUT hex 1 4 28 unf 3b steel and nylon 1 19 193757 BEARING 1 20 RETAINER spring 2 21 178189 SPRING compression steel 1 22 192656 PISTON cs 1 23 178226 SEAL piston glass filled PTFE 1 24...

Page 25: ...6 52 11 19 31 4 5 3 6 5 5 1 6 6 2 Torque to 276 324 in lbs 31 37 N m 1 Torque to 42 45 in lbs 4 5 N m Torque to 54 56 ft lbs 73 76 N m 3 Torque to 54 56 in lbs 6 0 6 5 N m 4 Torque to 40 48 ft lbs 54...

Page 26: ...Part No Description Qty 201 RECIPROCATOR page 24 1 202 25A168 SEAL gasket 1 204 108513 PIN 1 205 DISPLACEMENT PUMP 1 206 183741 LABEL identification 1 207 160742 PELLET nylon 1 FIG 33 Coupling joint s...

Page 27: ...aulic fluid input volume 60 cpm 3 gpm 11 lpm Hydraulic fluid consumption rate 6 5 ounces per cycle 0 195 l per cycle 1 gallon per 195 cycles Maximum fluid temperature 250 F 121 C Output per cycle 0 6...

Page 28: ...Technical Data 28 3A3005C Typical Fluid Outlet Pressure...

Page 29: ...id outlet adapter 3 4 NPT Hydraulic Outlet 3 53 89 6mm minimum diameter clearance hole 3 536 in 90 424 mm 3 536 in 90 424 mm clearance for or tap 5 16 18 typical 4 places ti25402 A B C D E E F F G 13...

Page 30: ...ial or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES E...