Graco 332514J User's Manual
Contents
1. 42 26 Thread shovel piston 216 to the end of priming rod 215 Hand tighten b Tighten nut using a socket wrench on nut 219 and a second wrench on flats of priming rod 215 turning in the opposite direction 17 Thread shovel cylinder 208 to pump cylinder 204 FiG 42 Use a wrench to tighten securely 18 Push displacement rod assembly up until displace ment rod 212 is extending out the top of the pump adapter 2 as shown in FIG 43 19 Apply a thin layer of grease to gasket seals 9 Install seals in pump adapter 2 as shown in FIG 43 212a FIG 43 20 Place spring 8 over the end of displacement rod 212 as shown in FIG 44 44 3325141 21 Remove pump assembly from vise Align hole 25 For Tube In Tube models only Install gasket 5 212a in displacement rod 212 FiG 43 with con and Tube In Tube 3 Secure Tube In Tube to necting rod hole 102b FiG 44 Insert pin 7 pump adapter 2 using screws 4 Use a socket to through hole tighten bolts securely FIG 47 Torque to 7 9 ft Ibs 9 12 N m 22 Slide spring 8 over pin 7 to secure pin in place Seat spring in groove 1028 in connecting rod 102 NOTE Tube In Tube Replacement Kits 24T863 for to prevent it from moving during pump operation 60 pound pumps 241864 for 90 pound pumps and 241865 for 400 pound pumps are available from Graco See Parts page 38 for inf2. 25 20 15 10 Current Amp 332514J 42 Graph 3 HP Model at Ambient Temperature Dimensions Flowrate in min cm min 332514J N _ PLT ET ELT PELLET TET TET ETE ETT ETT AN LEN LL LLLA PETTITT TTT TTT ET ETT ET AT LLL LESSE IS re TTT TTT EE Current Amp 10 12 14 eee 0 psig 1000 psig 6 89 MPa 69 95 bar 2000 psig 13 79 MPa 137 9 bar 3000 psig 20 68 MPa 206 84 bar 4000 psig 27 58 MPa 275 79 bar 5000 psig 34 47 MPa 344 74 bar 43 Dimensions Graph 4 HP Model at 40 F 40 C Ns M E E m 2 A 1000 psig 6 89 MPa 69 95 bar 2000 psig 13 79 MPa 137 9 bar 3000 psig 20 68 MPa 206 84 bar MT 4000 psig 27 58 MPa 275 79 bar psie 3447 MPa 34474 bar Flowrate in min cm min Current Amp 44 332514J Notes 332514J Notes 45 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a pe
3. NA 16V999 VALVE pressure relief 5000 psi PL MPa o _ 115122 VALVE pressure relief 4000 psi CO 0 _ 38 3325141 Technical Data Technical Data Dyna Star HP or HF Lubrication Pump Maximum Working Pressure HF Models 3500 psi 24 1 MPa 241 bar HP Models 5000 psi 34 47 MPa 344 bar Electrical Requirements All Models Wire Terminal AWG Size for Control Board Input Voltage Range 24 VDC ON OFF Signal Voltage Range and Current Voltage Range Drive Resistance Peak Operating Current 24 VDC Peak Power 24 VDC Pump Output HF Models HP Models 24VDC 24 to 10 AWG 18 to 32 VDC 5 to 32 VDC 1 1K 720W See Performance Charts beginning on page 41 Tank Resenor ob 22000 Wetted Parts Pump Wetted Parts steel polyurethane acetal buna N aluminum polyester elastomer Operating Temperature 40 to 65 C 40 to 65 Audible Sound Presse O yo 1000 psi 6 89 MPa 58 95 bar Models 714 dB A 3000 psi 20 68 MPa 206 84 bar Models 5000 psi 34 47 MPa 374 74 bar Models 70 6 dB A Cable Cable Gland Thread M25 Cable Range 0 36 0 64 in 9 16 cm Sound power was measured per 5 9614 2 332514J 39 Dimensions Dimensions 60 Pound Models 90 Ib Models 400 Ib Models US neh 10 6 268 10 6 11 0 40 332514J Dimensions Performance Charts To find the Current Amp at a specified Flow Rate To find the Flow Rate
4. 16F774 CYLINDER pump 16T704 CYLINDER 90 120 spacer model did ST 16T818 CYLINDER spacer 400 model 167819 CYLINDER spacer 35 60 model 306 GASKET T SEAL intake SERE Ra T 208 162775 CYLINDER shov 1 gt i O RING 1 SEAL retainer retainer 212 161703 ROD displacement 90 120 model hE a 167810 ROD displacement 400 model 167811 displacement 35 60 model terea 7213 16 7 ROD piston S07 ma t SEAL piston iC 7215 16 043 ROD priming T 7216 16F944 PISTON shovel 50 7 hp t PIN stright 7219 16602 NUT h T Included in Seal Kit 24T861 37 Parts List Pump Lower Parts Cable Harness Kits PartNo Description 77 527 CABLE power series progressive system id a 77 529 power injector system only Use Snow 77 528 CABLE power extension 15 ft 4 6 m Used e n 24N402 CABLE 6 ft vent valve 2 pin for vent valve iud REN Repair Kits Description 24T860 KIT seal HP models RIT seal HP modes Accessories 205 215 Helated Description Manual 77X522 Level and Dipstick 332515 77 530 Stick 90 332515 77 531 Stick 60 332515 77 540 Vent Valve pump mounted 332519 NA NA 208 16X171 KiT outetmanitod
5. 60 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 61 on the Vent Valve or Manifold FiG 61 Lubricant Outlet Connection 10 Connect power to pump 11 See Operation instructions for pump priming and reservoir filling instructions page 15 332514J Hepair Motor Control Board Replacement Kit 24T867 e Reference numbers used in the following instruc tions refer to Parts pages beginning on page 35 e Upper case letters used in the following instructions refer to Typical Installation provided on page 6 or 7 e Lower case letters used in the following instructions refer to component parts or user provided parts e Unless otherwise noted keep all parts for reassem bly Inspect and clean parts as needed prior to using them for reassembly e 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 8 3 Disconnect Timer Controller F user supplied if used 4 Disconnect High Pressure Lubricant Supply Line D to the Lubricant Output Connection 0 FIG 62 on the Vent Valve or Manifold e 2 ai 54 uU o 4 s a S e 0 62 Lubricant Outl
6. AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have requ
7. and washers 124 holding motor 123 to gear box housing 101 Remove motor Verify o ring 122 was removed with motor FIG 56 If o ring 122 is still inside the gear box housing 101 remove it Discard these parts in accordance with all safety regulations 56 3325 14J 29 Repair Reassembly 5 Match green yellow and blue wires to terminals of same color written on the motor control board NOTE Secure wires to terminals using washers and nuts 134 and 135 FiG 59 Torque to 8 10 in lbs 0 9 1 1 N m FIG 57 3 Use all new parts included in kit for reassembly Apply a thin coating of Gleitmo 585K grease to shaft of the new motor Apply a thin layer of grease to o ring 122 Install o ring in motor 123 FiG 57 Install new motor 123 using screws 125 and washers 124 FiG 57 Use a wrench to tighten screws securely Torque to 17 19 ft lbs 23 25 N m Feed motor wire harness 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 Tighten coupling nut CN to 2 0 ft lbs 2 7 N m FIG 59 6 Connect sensor cable 117a FIG 59 7 Replace control board gasket 119 and cover 120 with screws 116 being careful not to pinch any 58 30 3325 14J wires Tighten screws securely Torque to 17 19 ft lbs 23 25 N m Fic
8. e Protective eyewear and hearing protection e Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturers 3325 14J 5 Typical Installation Injector System Typical Installation Injector System The installation shown in below is only a guide for selecting and installing system components distributor for assistance in planning a system to suit your needs ALS 24 Battery 4 7 I e 2 2 lt lt lt 1 Front FiG 1 Lubricant output connection K Reservoir Tank Pump L Vent Valve for reference only Ignition switch M Motor High pressure lubricant supply lines Injector banks Lubrication controller Fill port for reference only non tube in tube models only Overflow port for reference only Breather for reference only User provided cC TOoOnmoou z 7 A Contact your Graco Controller Capabilities Low Reservoir Level Switch Level Indicator optional Pressure Switch for System Control Remote Alarm Device Light or Horn user provided Motor Control Board 3325141 Typical Installation Series Progressive System Typical Installation Series Progressive System The installation shown below is only a guide for selecting and installing system compon
9. min 332514J Operation Upper case letters used in the following instructions refer to Typical Installation provided on page 6 or 7 Be sure unit is securely mounted and grounded before operation Do not lift pressurized equipment 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 the high pressure lubricant supply line D to outlet Fill Reservoir Do not insert finger into the overflow port while filling a reservoir equipped with a follower plate 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 inspect lubrication level Do not fill reservoir beyond overflow port H Do not use breather vent as a port to fill reservoir 332514J Operation COMPONENT RUPTURE HAZARD The maximum working pressure of each component in the system may not be the same Over pressuriz ing any component can result in rupture fire explo sion property damage and serious injury To reduce the risk of over pressurizing any compo nent in the system be sure you know the maximum working pressure of each component Never exceed the maximum working pressur
10. the current limit by turning on motor control board is set too the Current Control Potentiometer low Knob clockwise Separate motor from pump and run motor If motor is damaged replace motor See Motor Replacement instructions page 28 Pump lower is plugged Follow Seal Replacement instruc tions to disassemble pump lower Inspect and clean parts as needed prior to using them for reassembly Replace all 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 System pressure too high Reduce system pressure by installing larger diameter lubrication tubes Current Control Potentiometer Knob Increase the current limit by turning G on control board is set too low the Current Control Potentiometer Knob G clockwise Separate motor from pump and run motor If motor is damaged replace motor See Motor Replacement instructions page 28 Motor control switch J is set to PWR Change motor control switch J to mode Pump cycling is controlled by signal mode SIG signal output and pump is running Motor is damaged Locked rotor 2 blinks Motor temperature is high 4 blinks Motor is damaged continuously High duty cycle Reduce duty cycle Loose or damaged HALL sensor Verify HALL sensor cable is securely cable attached Tighten connection Replace da
11. 5000 psi 34 47 MPa 344 bar models 77 000 77 001 77X002 77 003 115122 VALVE pressure relief 4000 psi 27 6 MPa 276 bar models 77X011 77 012 77X013 77X014 77X015 77 016 77 540 KIT vent valve also includes 12 13 15 16 17 included with models 77 011 77X012 77 013 only Can be added to other models 719 247862 KIT motor replacement 1 29A 160728 LABEL safety warning T 304 15 108 LABEL safety pinch 2 CABEgad OHNGMB5 32 33 ASSEMBLY pump lower see page 37 and 38 332514J Parts List A Replacement Danger and Warning labels tags and cards are available at no cost Included Tube In Tube Kit 241863 60 pound 247864 90 pound 241865 400 pound Included in Seal Kit 24T860 T Included in Seal Kit 24T861 Included in Outlet Manifold Kit 16X171 e Included in Vent Valve Kit 77X540 Included in Cable Gland Kit 77X533 31 32 35 Parts List Gear Box Description 301 __ HOUSING gearbox CT mo ROD connecting CT 103 BRACKET gear boxtopump T m04 SCREW 8 z 1 gt ms GEAR firststage wbearing T ma retaining ema fT HOUSING ger 16 SCREWS M8 TT BOARD conr T 18 SCREW machine philips pan head 4 m9 SEAL box cover T 120 controrbox 101 36 122 1628
12. in min at a specified cur in3 min rent Amp 1 Locate the specified Flow Rate on the vertical axis 1 Locate the specified Current on the horizontal axis 2 Follow the horizontal line to the intersection with the 2 Follow the vertical line up to the intersection with the System Operating Pressure System Operating Pressure 3 Follow the vertical line down to determine the aver 3 Follow the horizontal line across to determine the age current required Flow Rate Graph 1 HF Model at Ambient Temperature 40 655 48 35 573 55 30 491 61 N 409 68 1000 psig 6 89 MPa 69 95 bar 827 74 2000 psig 13 79 MPa 137 9 bar 3000 psig 20 68 MPa 206 84 bar m Ui Flowrate in min cm min N 245 81 3500 psig 24 13 MPa 241 32 bar 10 163 87 5 81 94 0 2 4 6 8 10 12 14 16 18 20 Current Amp 332514J 41 Dimensions HF Model at 14 F 10 C Graph 2 2000 psig 13 79 MPa 137 9 bar 3000 psig 20 68 MPa 206 84 bar 3500 psig 24 13 MPa 241 32 bar O psig 1000 psig 6 89 MPa 69 95 bar LLLLLLLLLLEEELEELEELELECLLEEELELLLLL SASN ATTN A EEA N EEE NAN PST EET LTN SASS AAAA ETT ETT TTT MNIE N 1 81 94
13. 0 being careful not to pinch any wires Tighten screws securely Torque to 17 19 ft lbs 23 25 Fic 70 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 Fic 71 Lubricant Outlet Connection 8 Connect power to pump 9 See Operation instructions for pump priming and reservoir filling instructions page 15 34 332514J Parts List Main Assembly Models Description 1 BOX gear model page 36 B 247897 KIT adapter pump HP models T 3 KIT adapter pump HF models EN TUBE IN TUBE 60 includes 4 m TUBE IN TUBE 120 includes 4 TUBE IN TUBE 400 includes 4 uv NN 4 SCREW shcs M6 x 25 models A ron 5 fill tube flange models 77 001 77X002 77X003 77X01 1 77 012 77X013 6 __ SCREW shes M 0X9088T 4 7 ie PN pump SCC 8 119 78 SPRING retaining GASKET seal 11 ADAPTER outlet models 77 000 77X001 77X002 77X003 77X014 77X015 77X016 12 ORNe FMD 2 13 SCREW cap models 77X000 77X001 77X002 77X003 77X014 77X015 77X016 SCREW cap models 77X011 77X012 77X013 included in kit 77X540 14 LABEL seria T 15 6 PLUG pipe 31 16 16V999 VALVE pressure relief
14. 41 PACKING o ring 1233 v7 7 MOTOR 24VDC WASHER lock SCREW hex head 126 3 COVER shroud COVER shroud i T Hm 9 NUT 9 e l1WASHER 16 Included in Control Board Kit 241867 Included in Shroud Kit 24T866 Included in Motor Kit 24T862 Included in Motor Control Board Seal Kit 240827 NOTE Kit 240827 only includes quantity 4 116 Screws 332514J HP Model Pump Lower 167857 16N700 161757 Description 2 2 7 KIT adapter pump 7 7201 156530 NUT reamer 1 NL 15C537 CYLINDER pump 16N718 CYLINDER spacer 35 60 model didi EM 16N686 CYLINDER spacer 90 1202 model lE MM 16T753 CYLINDER spacer 4002 model Bal NNNM 206 GASKET se 207 SEAL intake Sk sie T 208 1925639 CYLINDER shovel 209 O RING retainer S retainer 212 16N719 ROD displacement 35 60 model pur 16N687 ROD displacement 90 120 model 167754 ROD displacement 4002 model et tr za on ae irae ROD shovel 580 T 216 164249 PISTON shovel 80186 T 271 PiNvstaight 12 Included in Seal Kit 247860 332514J Parts List HF Model Pump Lower 16 706 16T821 16T822 Description 2 2 KIT adapter pump 1 7201 166947 NUT retainer BLISS
15. Instructions gt 7 GRACO 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 Important Safety Instructions Read all warnings and instructions in this manual Save these instructions e Models Page 2 rej 4 PROVEN QUALITY LEADING TECHNOLOGY Models Models Compatible Reservoirs Maximum Working Pressure Pump Tubein Vent 7 Valve 35 60 90 120 400 3500 5000 Pound Pound Pound 24 1 MPa 241 bar 34 47 MPa 344 bar meo J x 1 j x J 111 X me x x X x mew x x pid gt mee x x T Prot x x Pre x x X1 X xf Pros x x X1 1 x x moa ed x Ems X X xf mew 1 1 X1 d Xd X 2 332514J Warnings 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
16. ce pump seals See Seal Replacement instructions page 19 Current Control Potentiometer Knob the current limit by turning on motor control board is set too the Current Control Potentiometer low Knob clockwise Flow Control Potentiometer Knob Increase the flow limit by turning the on motor control board is set too low Control Potentiometer Knob H clockwise Leakage in a lubrication line Check lubrication line for leakage Pump is cycling there is output of Replace any lines that are leaking fluid at the outlet pump pressure is and or damaged not building Pump seals are worn or damaged Replace pump seals See Seal Replacement instructions page 19 Pump not powering ON green LED is not ON Pump is cycling but there is no lubricant output from the outlet Pump is cavitating Pump is cycling slow 16 332514J Troubleshooting Pom me Soo Hed fault LED E on control board blinking Over current fault 1 blink System pressure too high system pressure by installing larger diameter lubrication tubes Current Control Potentiometer Knob the current limit by turning on motor control board is set too the Current Control Potentiometer low Knob clockwise System pressure too high system pressure by installing larger diameter lubrication tubes Current Control Potentiometer Knob
17. cement 5 Loosen bolts 128 and remove cover 126 from D Kits 24T860 HP Models 24T861 HF Models pump oed e Reference numbers used in the following instruc tions refer to Parts pages beginning on page 35 e Upper case letters used in the following instructions refer to Typical Installation provided on page 6 or 7 e Lower case letters used in the following instructions refer to component parts or user provided parts e Unless otherwise noted keep all parts for reassem bly Inspect and clean parts as needed prior to using them for reassembly e Use all new parts included in kit for reassembly 126 FiG 17 6 Remove screws a and washers b holding Dyna Star Pump to cover and remove pump from cover FiG 18 Place pump on a workbench or 1 Disconnect Dyna Star pump from main power table top protected with a drop cloth source Disassembly uw 2 Relieve pressure see Pressure Relief procedure page 8 3 Disconnect Timer Controller F user supplied if used 4 Disconnect High Pressure Lubricant Supply Line D to Lubricant Output Connection 0 FIG 11 on the Vent Valve or Manifold 16 Lubricant Outlet Connection 332514J 19 Repair 7 For Tube In Tube models only Remove bolts 4 e Usea screw driver to turn motor shaft clockwise holding tube 3 to pump adapter 2 Remove tube until shovel piston 216 is seated in the lowest a
18. e 15 FiG 11 Lubricant Outlet Connection 10 Wiring Grounding 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 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 NOTICE Fuses user supplied are required on all models To avoid equipment damage e 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 3325 14J Wiring Installation Instructions 4 Route wires into box Replace gasket 119 cover MEM 120 and screws 116 being careful not to pinch Reference numbers used in the following instructions any wires Tighten bolts securely Torque bolts to refer to Parts page 36 17 19 ft lbs 23 26 N m 1 Remove screws 116 cover 120 and gasket 119 to access motor lead wires FIG 12 2 Feed the incoming power source wires through the strain relief body SR and into the gear housing FIG 12 a Tighten the strain relief body SR to the gear housing 115 to 5 1 ft Ibs 7 0 N m b Tighten the compression nut CN to 3 7 ft lbs 5 0 N m NOTE See Technical Data page 39 for wire O D spec Fic 12 ifications to verify correc
19. e of the lowest rated component in the system Regulate pressure to the pump so that no fluid line component or accessory is over pressurized Never allow pump to run dry of the fluid being pumped Running a pump dry can damage the pump Shutdown For normal system shut down disconnect power to lubricator controller F and pump B to control board 15 Troubleshooting Troubleshooting Wiring not done correctly polarity is Check wire connections Verify they wrong or loose wire s are all tight Correct polarity Fuse not in place or fuse is faulty Check fuse rating If incorrect fuse is used install fuse of the correct amperage Lubrication controller is in OFF mode Set lubrication controller to correct lube cycle Pump is powered on green LED is Motor is not wired properly to control Connect wires to correct color ON but pump is not cycling board terminals Pump is powered on green LED is Pump control switch J is set to Change pump control switch J blinking pump cycles continuously mode Pump is not signal mode SIC instead of turning OFF controlled by signal output Lubricant level in tank reservoir is too Refill tank reservoir low Damaged tank or reservoir tank reservoir Shake tank reservoir to redistribute grease Install a follower plate to help distribute grease during pump operation Pump seals are worn or damaged Hepla
20. ents 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 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 332514J Secondary metering device 7 lt Controller Capabilities Low Reservoir Level Switch Level Indicator optional Remote Alarm Device Light or Horn user provided Motor Control Board FiG 2 Installation Installation Pressure Relief Follow the Pressure Helief Procedure whenever you see this symbol K Nex ww 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 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 7 d P FIG 3 Pump Module Reference numbers
21. et Connection 31 Repair 5 Remove screws 116 from motor control box cover 7 Disconnect sensor cable 117a from motor control 120 and remove cover and gasket 119 FIG 63 board FIG 65 8 Disconnect source to power input A and B and pump control connections C and D See Fic 65 and Control Panel page 13 FIG 63 6 Remove nuts 134 as shown in FIG 64 Remove washers 135 and motor wires from terminals FiG 65 9 Remove screws 118 securing motor control board 117 to housing 115 FiG 66 FIG 66 10 Remove motor control board from housing and dis pose in accordance with all safety regulations 32 3325141 Repair Reassembly 3 Match green yellow and blue wires of motor to ter minals of same color written on the control board NOTE Secure wires to terminals using washers 135 and e Use all new parts included in kit for reassembly eet FiG 59 Torque to 8 10 in Ibs 0 9 1 N m 1 Install new motor control board 117 in housing 115 using screws 118 67 Torque to 8 10 in 5 0 9 1 1 N m Fic 67 2 Connect source to power input A and B and pump signal connections C and D Fic 65 and A B C D page 13 Torque to 5 5 7 in lbs 0 62 0 79 N m 69 4 Connect sensor cable 117 69 Fic 68 332514J 33 Repair 5 Replace motor control board gasket 119 and cover 120 with screws 116 FIG 7
22. ily 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 Houte 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 e Keep clear of moving parts e Do not operate equipment with protective guards or covers removed e Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure and disconnect all power sources 4 3325 14J Warnings BURN HAZARD 77 Equipment surfaces and fluid that s heated can become very hot during operation avoid severe burns e 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
23. immediately 332514J 3 Warnings PRESSURIZED EQUIPMENT HAZARD Over pressurization can result in equipment rupture and serious injury e 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 fluids containing such solvents e 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 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 da
24. in 7 out of hole FIG 25 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 for reassembly FIG 26 FIG 24 FIG 26 14 Secure pump adapter 2 section in a brass vise NOTE To protect the outside surface of the pump place a rag around the pump body before putting pump in vise jaws 15 The pump cylinder is comprised of 3 separate sec tions Separate the shovel cylinder section 208 from the pump cylinder 204 first using two pipe 3325 14J 21 Repair wrenches working in opposite directions to loosen shovel cylinder When cylinder 208 is loose enough use your hands to unscrew and remove it from the other sections FIG 27 FIG 27 16 bf HP Pump Use wrench on flats of priming rod 215 and socket to loosen and remove shovel piston 216 FiG 27 HF Pump a Use wrench on flats of priming rod 215 Hemove hex nut 219 b Unscrew shovel 216 and remove it from prim ing rod 215 Use a wrench on the flats 211a of seal retainer 211 and a strap wrench working in the opposite direction on pump cylinder 204 to loosen and remove adapter and o ring 209 from pump der 204 FiG 28 Discard o ring Use the new o ring included in the kit for reassembly 211a 215 Fic 28 22 18 Separate pump cylinder 204 fr
25. inside pump adapter 2 if it did not come out with the spacer inder 205 Discard gasket seal Use gasket seal included in the kit for reassembly Use a socket to loosen hex nut 201 and remove it from the pump adapter 2 FiG 32 332514J Hepair FiG 32 27 Use the displacement rod 212 to push the packing u cup 202 out of the pump adapter 2 in the direc tion shown in FiG 33 Discard u cup 202 A new one is included in the kit FIG 33 23 Repair Reassembly NOTE Before reassembly carefully clean and inspect all parts and pump surfaces for scratches and damage A pump with damaged parts will not hold pressure or operate efficiently Use all new parts included in kit for reassembly Apply a thin layer of grease to the packing u cup 202 Use a flat blunt end tool to seat u cup 202 with the lips facing down into the pump adapter 2 FIG 34 NOTE Do not damage u cup seal on threads during installation FIG 34 3 24 Install hex nut 201 inside pump adapter 2 Use a wrench to tighten nut securely FIG 34 Torque to 18 22 ft lbs 24 30 N m Apply a thin layer of grease to the surface of dis placement rod 212 Slide rod into the pump adapter 2 in the direction shown in FIG 35 only NOTICE Sliding displacement rod 212 into the pump adapter from the other side of the pump adapter 2 could damage the throat seal 201 resulting in a poor seal a
26. ired that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6928 or Toll Free 1 800 533 9655 Fax 612 378 3590 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice For patent information see www graco corypatents Original instructions This manual contains English MM 332514 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2013 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com February 2015
27. ket over end of spacer cylinder 205 Slide cylinder over rod assembly as shown in FIG 39 Thread end of cylinder into bottom of pump adapter 2 Use a pipe wrench to turn cylinder until tightened securely Torque to 45 55 ft lbs 61 74 N m Cm FIG 39 11 Apply a thin layer grease to seal 206 and install around pump cylinder 204 FiG 40 12 Apply a thin layer of grease to piston seal 214 13 Thread pump cylinder 204 to spacer cylinder 205 Use a wrench to tighten securely Torque to 45 55 ft lbs 61 74 N m 14 Apply a thin layer of grease to intake seal 207 and install seal with lips facing up inside pump cylinder 204 as shown in FIG 40 214 FIG 40 25 Repair 15 Apply a thin layer of grease to o ring 209 and install around the seal retainer 211 FIG 41 16 Thread seal retainer 211 to pump cylinder 204 with the seal end installed inside the pump cylinder as shown in FiG 41 Use a wrench on the nut 211a to tighten adapter nut securely Torque to 18 22 ft lbs 24 30 N m 211a 204 Fic 41 HP Pump Thread shovel piston 216 to the end of priming rod 215 Use a socket wrench on piston 216 and wrench on the flats of priming rod 215 to securely tighten shovel piston FiG 42 Torque to 145 to 155 in 105 16 17 N m NOTE Be careful when tightening the nut that the rod assembly does not twist and break the support pins 217 or bend any of the rod sections
28. maged cable blinks 5 blinks Separate motor trom pump and run motor If motor is damaged replace motor See Motor Replacement instructions page 28 Missing temperature sensor Motor is damaged 3325 14J 17 Troubleshooting Pobm Cause Soon System pressure too high system pressure by installing larger diameter lubrication tubes Current Control Potentiometer Knob the current limit by turning G on control board is set too low the Current Control Potentiometer Knob G clockwise Separate motor from pump and run motor If motor is damaged replace motor See Motor Replacement instructions page 28 Motor control switch J is set to PWR Change motor control switch J to mode Pump cycling is not controlled signal mode SIG by signal output and pump is running continuously High duty cycle Reduce duty cycle HALL sensor cable not securely Verify HALL sensor cable is securely Loose or damaged HALL sensor attached attached Tighten connection cable 7 blinks Damaged HALL sensor cable Replace motor Motor runs but pump does not Motor shaft gears are stripped or Gear box is damaged Replace damaged pump Control board LED s blink erratically Damaged control board Replace motor control board See Motor Control Board Replacement instructions page 31 Control board temperature is high 6 blinks Motor is damaged 18 3325141 Repair Repair Seal Repla
29. nd fluid leakage during operation FIG 35 5 Slide together piston rod 213 and piston seal 214 Fic 36 213a FIG 36 6 Thread piston rod 213 into end of displacement rod 212 Hand tighten the two pieces together securely ending with hole 213a FIG 36 aligned with hole 212a FIG 37 3325 14J 7 Install pin 217 through aligned holes 213a FIG 36 and 212a FIG 37 Support rods 212 and 213 as needed to ensure the rods do not bend Use a pick and hammer to seat the pin inside the rods NOTE Be sure pin 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 7 FIG 37 8 Thread priming rod 215 into end of piston rod 213 Hand tighten the two pieces together securely ending with hole 215a aligned with hole 213b FIG 38 9 Install pin 217 through the aligned holes 215a and 213b Fic 38 Support rods 215 and 213 as needed to ensure the rods do not bend Use a pick and hammer to seat the pin inside the rods NOTE Be sure pin 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 FIG 38 332514J Hepair 10 Apply a thin layer of grease around gasket 206 Install gas
30. nd gasket 5 and set these parts aside to use for reassembly FIG 19 position inside the shovel cylinder 208 NOTICE Pump has a one way clutch Do not use a power screwdriver to turn shaft or not turn shaft counter clockwise These actions could damage pump motor FIG 19 8 Observe location of priming rod 215 and shovel piston 216 inside the shovel cylinder 208 See Pump Parts page 38 If the piston is not located in the lowest position inside the cylinder c Remove screws 125 and washers 124 hold ing motor 123 to gear box housing 101 Fic f Verify o ring 122 is still in place and correctly 20 seated in motor 123 FiG 20 d Remove motor g Reinstall motor 123 to gear housing box 101 using screws 125 and washers 124 Use a wrench to tighten screws securely Torque to 12 14 ft lbs 16 19 FIG 20 Remove screws 6 from pump adapter 2 FIG 22 20 FiG 22 20 3325141 10 Pull pump adapter 2 down to access retaining 12 Separate displacement rod 212 from connecting spring 8 FIG 23 rod 102 and separate these sections Put section 102 in a safe place You will need it for reassem bly FIG 25 NOTE Be careful when pulling these sections apart that you do not lose spring 8 FIG 23 11 Slide spring 8 out of groove 102a in connecting rod 102 to expose pump pin 7 FiG 24 Push or tap pump p
31. om spacer cylinder 205 using two strap wrenches working in opposite directions to loosen spacer cylinder When cylinder 204 is loose enough use your hand to unscrew and remove it from the other section FIG 29 207 204 d 206 CP 4 215 A 214 217 213 205 FIG 29 19 Remove intake seal 207 and seal 206 Discard these parts Use new parts included in the kit for reassembly 20 Use a hammer or rubber mallet to tap the rod assembly out of the pump adapter 2 in the direc tion shown in FIG 30 lcm UC ERN m J rod assembly lt 4 FIG 30 332514J 21 FIG 22 23 24 25 26 Use a punch and hammer to tap out pins 217 hold ing the rod sections together FIG 31 Use your hands to unscrew shovel rod 215 and spacer rod 212 from piston 213 215 217 31 Remove piston seal 214 from piston 213 Dis card piston seal 214 and pins 217 New replace ment parts are included in the kit Visually inspect rod sections and the inside surface of pump cylinder 204 to verify they are not bent or damaged following disassembly A pump with bent and or damaged parts will not hold pressure and or operate efficiently 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 from the pump Hemove gasket seal 206 from
32. ontrol Potentiometer Minimum Turn Knob Counter Clockwise Maximum Turn Knob Clockwise Pump Control Switch e PWHR Turns pump on when power is applied e SIG Turns pump on when voltage is applied to SIG IN SIG IN Blue Motor Wire Connection Yellow Motor Wire Connection Green Motor Wire Connection J5 Connector Motor Hall Cable Connector 332514J Wiring Low or High Voltage High Motor temp Missing Temp Sensor High Board Temp Bad Hall Cable NOTE Be sure power to pump is OFF before switching between the PWR and SIG modes 13 Wiring Current Control and Flow Motor Control Settings Current and Flow control are adjusted on the Motor Control Board using the Current Control Potentiometer Knob G and the Flow Control Potentiometer Knob H page 13 Turn knob to clockwise to increase setting value Turn knob counter clockwise to decrease setting value 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 for Flow Rate and Current information NOTE Values are based on lab test conditions at ambient temperature 72 F 22 C with an input voltage of 24V Actual results may very and should be verified in the application HF Current HP Current 14 Amps Amps 30 HF Flow 20 10 in min HP Flow 10 5 15 20 in
33. ormation about ordering these kits or contact your Graco Distributor or Graco Customer Service 23 Align the two gasket seals 9 in pump adapter 2 with two holes 103b in gear box pump bracket 103 Push the pump lower and pump assembly together FIG 45 FIG 47 26 Align holes in pump base with holes in tank reser voir cover Securely fasten pump to tank reservoir cover using screws a and washers b FIG 48 FIG 45 24 Secure pump adapter 2 to pump upper pu using screws 6 Use a socket to tighten screws securely NOTICE FIG 46 Torque to 7 9 ft Ibs 9 12 N m Be careful when installing pump to base that wire har ness to motor is not caught between the pump and the hole on top of the reservoir If the wire harness is caught between the pump and reservoir the wires could be damaged Fic 46 48 3325141 27 Repair NOTE When the pump is correctly installed the breather J will be below the control box 115 as shown in FIG 49 FIG 49 27 Reinstall cover 126 using bolts 128 Use a wrench to tighten bolts securely FIG 50 28 Connect the timer controller F user supplied if used 29 Connect High Pressure Lubricant Supply Line D to the Lubricant Output Connection 0 FIG 51 on Vent Valve or Manifold c f gt Fic 51 Lubricant Outlet Connection 30 Connect power to pump 31 See Operation ins
34. ries 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 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 332514J Installation FiG 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 9 133 FiG 9 NOTICE To prevent damage to the unit Check breather J vent for proper operation before filling reservoir Open overflow port before filling reservoir to visually inspect lubrication level Do fill reservoir beyond overflow port Do not use breather vent as a port to fill reservoir 7 Reinstall cover 126 using bolts 128 Use a wrench to tighten bolts securely FiG 10 Wiring 126 10 8 Connect the timer controller user supplied if used 9 Connect High Pressure Lubricant Supply Line D to the Lubricant Output Connection 0 Fia 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 pag
35. riod of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of 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 EXCLUSIVE
36. t cable is used 3 Make all source to input power connections A and page 13 and pump control connections C and D page 13 Refer to Fic 13 or FIG 14 page 12 for wiring diagrams and Control Board diagram page 13 To avoid equipment damage remove power before switching modes from signal to power or power to sig nal 332514J 11 Wiring 24 VDC With Signal Input Motor Control Board Pump Output Lubrication Controller Pump Output Electric Vent Valve Fic 13 Pump control switch shown in signal mode A Vent Valve is only used in an injector based system 24 VDC With External Relay Motor Control Board 35A 2 2 40 ul m TEE Sig In Pump Output 5 32VDC Sig In Lubrication Controller Pump Output Electric Vent Valve Fic 14 Pump controls switch shown in power mode A Vent Valve is only used an injector based system 12 3325 14J DC Models Motor Control Board CURRENT ij Fic 15 Key gt Negative Power Input Positive Power Input Turn On Signal Turn On Signal Fault LED Blinks type of fault See Fault Table Green Power LED e Blinks Power ON Pump running Solid Power Pump OFF Current Control Potentiometer Minimum Turn Knob Counter Clockwise Maximum Turn Knob Clockwise Flow C
37. tructions for pump priming and reservoir filling instructions page 15 28 Motor Replacement Kit 24T862 Reference numbers used in the following instruc tions refer to Parts pages 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 component parts or user provided parts Unless otherwise noted keep all parts for reassem bly Inspect and clean parts as needed prior to using them for reassembly Use all new parts included in kit for reassembly Disassembly ja Disconnect Dyna Star pump from main power source Relieve pressure see Pressure Relief procedure page 8 Disconnect Timer Controller F user supplied if used Disconnect High Pressure Lubricant Supply Line D to the Lubricant Output Connection 0 FIG 52 on the Vent Valve or Manifold 52 Lubricant Outlet Connection 3325 14J Repair 5 Remove screws 116 from motor control box cover 7 Disconnect sensor cable 117a from motor control 120 and remove cover and gasket 119 FIG 53 board FIG 54 8 Use a wrench to loosen strain relief a and remove wiring harness from housing FIG 55 FIG 53 6 Remove nuts 134 as shown in FIG 54 Remove washers 135 and motor wires from terminals Save these parts to use them for reassembly FIG 55 9 Remove screws 125
38. 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 e 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 e 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 FiG 4 120 Pound Cover Shown 2 Loosen bolts 128 and remove cover 126 from Dyna Star pump FIG 5 126 FiG 5 3 Remove protective cap d from pump down tube 208 FiG 6 Discard cap You will not use it again 332514J 208 FiG 6 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 HEAVY EQUIPMENT HAZARD Lifting or moving heavy equipment incorrectly can cause serious injury To avoid serious injuries such as muscle strain or back inju
39. 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 e Do not point dispensing device at anyone 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
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