Graco Dyna-Star 77X000 Instructions Manual Download

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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.

Summary of Contents for Dyna-Star 77X000

Page 1: ...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 S...

Page 2: ...patible 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...

Page 3: ...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 o...

Page 4: ...ee 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...

Page 5: ...MENT 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...

Page 6: ...gh 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 onl...

Page 7: ...ure 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 on...

Page 8: ...ist 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 cov...

Page 9: ...5 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 serio...

Page 10: ...ing 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 0 D The equipment must be bonded grounded dire...

Page 11: ...CN to 3 7 ft lbs 5 0 N m NOTE See Technical Data page 39 for wire O D spec ifications to verify correct cable is used 3 Make all source to input power connections A and B page 13 and pump control conn...

Page 12: ...stem FIG 13 Pump control switch shown in signal mode 35 A 18 32VDC 5 32VDC Sig In Sig In Sig Pwr Electric Vent Valve Motor Control Board Lubrication Controller Pump Output Pump Output FIG 14 Pump cont...

Page 13: ...Maximum Turn Knob Clockwise J Pump Control Switch PWR Turns pump on when power is applied SIG Turns pump on when voltage is applied to SIG IN SIG IN K Blue Motor Wire Connection L Yellow Motor Wire C...

Page 14: ...e The Current Control knob G governs flow The Current setting has precedence over the Flow Rate setting You may be limited in achievable Flow Rate by the Current setting See Performance Charts page 41...

Page 15: ...Injury or amputation could result 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 in...

Page 16: ...but there is no lubricant output from the outlet Lubricant level in tank reservoir is too low Refill tank reservoir Damaged tank or reservoir Replace tank reservoir Pump is cavitating Shake tank reser...

Page 17: ...l damaged and worn parts See Seal Replacement instructions page 19 Low or high voltage 3 blinks Faulty input line voltage Use a multi meter to check input line voltage measure 18 32 volts DC Motor tem...

Page 18: ...control switch J is set to PWR mode Pump cycling is not controlled by signal output and pump is running continuously Change motor control switch J to signal mode SIG High duty cycle Reduce duty cycle...

Page 19: ...prior to using them for reassembly Use all new parts included in kit for reassembly Disassembly 1 Disconnect Dyna Star pump from main power source 2 Relieve pressure see Pressure Relief procedure page...

Page 20: ...d Remove motor e Use a screw driver to turn motor shaft clockwise until shovel piston 216 is seated in the lowest position inside the shovel cylinder 208 f Verify o ring 122 is still in place and corr...

Page 21: ...sections apart that you do not lose spring 8 13 Remove spring 8 and two seals 9 Put spring in a safe place to use it for reassembly The seals 9 can be discarded Use the new seals included in the kit...

Page 22: ...mp cylinder 204 to loosen and remove adapter and o ring 209 from pump cylin der 204 FIG 28 Discard o ring Use the new o ring included in the kit for reassembly 18 Separate pump cylinder 204 from space...

Page 23: ...ure and or operate efficiently 24 Separate spacer cylinder 205 from pump adapter 2 using a strap wrench to loosen cylinder When cylinder 205 is loose enough use your hands to unscrew and remove it fro...

Page 24: ...dapter 2 Use a wrench to tighten nut securely FIG 34 Torque to 18 22 ft lbs 24 30 N m 4 Apply a thin layer of grease to the surface of dis placement rod 212 Slide rod into the pump adapter 2 in the di...

Page 25: ...is centered in the hole A pin that is not entirely seated could scratch the bore of the pump cylinder 204 during pump operation pre venting pressure from building and causing fluid to leak 10 Apply a...

Page 26: ...od assembly does not twist and break the support pins 217 or bend any of the rod sections HF Pump a Thread shovel piston 216 to the end of priming rod 215 Hand tighten b Tighten nut using a socket wre...

Page 27: ...and Tube In Tube 3 Secure Tube In Tube to pump adapter 2 using screws 4 Use a socket to tighten bolts securely FIG 47 Torque to 7 9 ft lbs 9 12 N m NOTE Tube In Tube Replacement Kits 24T863 for 60 po...

Page 28: ...s beginning on page 35 Upper case letters used in the following instructions refer to Typical Installation provided on page 6 or 7 Lower case letters used in the following instructions refer to compon...

Page 29: ...from motor control board FIG 54 8 Use a wrench to loosen strain relief a and remove wiring harness from housing FIG 55 9 Remove screws 125 and washers 124 holding motor 123 to gear box housing 101 Rem...

Page 30: ...ss a through strain relief opening 115a in housing 115 FIG 58 Thread strain relief body SR into opening 115a Tighten to 3 5 ft lbs 4 7 N m Tighten coupling nut CN to 2 0 ft lbs 2 7 N m 5 Match green y...

Page 31: ...ollowing instructions refer to Typical Installation provided on page 6 or 7 Lower case letters used in the following instructions refer to component parts or user provided parts Unless otherwise noted...

Page 32: ...able 117a from motor control board FIG 65 8 Disconnect source to power input A and B and pump control connections C and D See FIG 65 and Control Panel page 13 9 Remove screws 118 securing motor contro...

Page 33: ...ower input A and B and pump signal connections C and D FIG 65 and A B C D page 13 Torque to 5 5 7 in lbs 0 62 0 79 N m 3 Match green yellow and blue wires of motor to ter minals of same color written...

Page 34: ...19 ft lbs 23 25 N m 6 Connect the timer controller F user supplied if used 7 Connect High Pressure Lubricant Supply Line D to the Lubricant Output Connection 0 FIG 71 on the Vent Valve or Manifold 8...

Page 35: ...7X003 77X011 77X012 77X013 1 6 SCREW shcs M6 1 0X90 SST 4 7 15F856 PIN pump 1 8 119778 SPRING retaining 1 9 GASKET seal 2 11 ADAPTER outlet models 77X000 77X001 77X002 77X003 77X014 77X015 77X016 1 12...

Page 36: ...mp 1 104 SCREW M8 2 105 BOLT M8 2 112 PACKING o ring 1 113 GEAR first stage w bearing 1 114 RING retaining internal 1 115 HOUSING gear 1 116 SCREWS M8 11 117 BOARD control 1 118 SCREW machine phillips...

Page 37: ...16N700 1 16T754 ROD displacement 400 model 16T757 1 213 15G098 ROD piston 1 214 SEAL piston 1 215 15F296 ROD shovel 225 hp 1 216 16W249 PISTON shovel 50 1 hp 1 217 PIN straight 2 Ref No Part No Descri...

Page 38: ...65 KIT tube in tube 400 pound 24T866 KIT shroud 24T867 KIT control board replacement 24T897 KIT adapter pump HP models 24T898 KIT adapter pump HF models 24U827 KIT motor control board seal Part No Des...

Page 39: ...eginning on page 41 HP Models Weight Pump Only 35 60 lb Tank Reservoir 50 lb 22 7 kg 90 120 lb Tank Reservoir 55 lb 25 0 kg 400 lb Tank Reservoir 60 lb 27 2 kg Wetted Parts Pump Wetted Parts steel pol...

Page 40: ...Ref 60 Pound Models 90 lb Models 400 lb Models US inch Metric mm US inch Metric mm US inch Metric mm A 29 737 36 5 927 44 3 1125 B 16 8 427 16 8 427 16 8 427 C 10 6 268 10 6 268 10 6 268 D 11 0 279 1...

Page 41: ...re 3 Follow the vertical line down to determine the aver age current required To find the Flow Rate in3 min at a specified cur rent Amp 1 Locate the specified Current on the horizontal axis 2 Follow t...

Page 42: ...Dimensions 42 332514J Graph 2 HF Model at 14 F 10 C 573 55 491 61 409 98 327 74 245 81 81 94 163 87...

Page 43: ...Dimensions 332514J 43 Graph 3 HP Model at Ambient Temperature 327 74 294 97 262 19 229 42 196 64 163 87 131 10 98 32 65 55 32 77...

Page 44: ...Dimensions 44 332514J Graph 4 HP Model at 40 F 40 C 229 42 32 77 65 55 98 32 131 10 163 87 196 64...

Page 45: ...Notes 332514J 45 Notes...

Page 46: ...the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS...

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Graco Dyna-Star 77X000, Instructions Manual

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