Graco 332540E User's Manual
Contents
1. Model 77X102 Dyna Star Pump 60 Auto Fill Shut Off Reservoir Cover Vent Valve Model 77X103 Dyna Star Pump 90 Auto Fill Shut Off Reservoir Cover Vent Valve Ref No Part No Description Qty 1 77X011 KIT pump and vent valve includes 1a and 1b Dyna Star 60 models 77X100 see instruction manual 332514 77X012 KIT pump and vent valve includes 1a and 1b Dyna Star 90 models 77X101 see instruction manual 332514 la PUMP 1 1b VENT VALVE see instruction manual 1 332519 3 77X535 KIT reservoir 60 grease includes 1 3a 3l models 77X100 77X536 KIT reservoir 90 grease includes 1 3a 3l models 77X101 3a PLUG pipe 3c NUT flanged hex 3d SCREW cap flange head 3e BREATHER 3f 194868 GASKET cover 3g PAIL reservoir 60 included in kit 77X535 PAIL reservoir 90 included in kit 1 77X536 3h 16V394 COVER reservoir 3i 104663 PLUG pipe SA 195341 LABEL notice breather 9A 16U728 LABEL over pressurize warning 104 160727 LABEL pinch warning 4 4 3j 109114 SCREW cap 4 3k 15M442 GASKET pump 1 3 104572 WASHER lock spring 4 5 77X521 VALVE auto fill shut off see instruc 1 tion manual 332518 5a VALVE auto shut off 1 5b DIAPHRAGM assembly 1 5c TUBE vent valve 1 5d FITTING connector 3 8 in npt x JIC 2 5e BOLT M8 x 1 25 x2 mm 2 Bf SEAL auto shutoff valve 1 4 4 4 A Replacement Danger and Warning labels tags and cards are available at no cost 332540E2. user provided Motor Control Board M H o il K lt __ K N FIG 1 Key A Lubricant outlet connection M Motor B Pump N Fluid overflow container C Ignition switch P Pump remote filling station D High pressure lubricant supply lines R Reservoir remote filling station E Injector banks S Auto Fill Shut Off F Lubrication controller G Fill port not used with Auto Fill Shut Off User provided H Overflow port not used with Auto Fill Shut Off J Breather K Reservoir L Vent Valve 332540E 5 Typical Installation Series Progressive System 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 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 L M Fed a N PA Ty i Kk k G oo Front FIG 2 Key A Lubricant output connectiont t The pump outlet requires modification to convert an Injector based B Pumpt system to Series Progressive system Dyna Star HF and HP Outlet C Ignition switch Adapter Kits 77X543 rated 4000 psi 275 8 bar 27 58 MPa and D High pressure lubricant supply lines 77X544 rated 5000 psi 344 7 bar 34 47 MPa are available from
3. E Primary metering device Graco Contact Graco Customer Service or your local Graco distribu mec tor to identify the correct kit for your installation location 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 Installation Pressure Relief Follow the Pressure Relief Procedure whenever you see this symbol 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 and no more lubricant or air is leaking from fitting as shown in FIG 3 FIG 3 332540E Installation 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 com ponent in the system Overpressuriz
4. reservoir instead of the fill port G When the grease level in the tank is full the Auto Fill Shut Off automatically ends the filling operation Refer to the Auto Fill Shut Off Kit instruction manual 332518 for complete instructions and additional information 8 332540E Filling Reservoir There are two reservoir filling options Fill Port G or Auto Fill Shut Off S Only one method of filling can be used Filling Reservoir With Fill Port G NOTICE To prevent damage to the unit e 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 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 NOTICE Never allow pump to run dry of the fluid being pumped Running a pump dry can damage the pump 332540E Operation Filling Reservoir With Auto Fill Shut Off S Refer to Auto Fill Shut Off Kit instruction manual 332518 Shutdown For normal system shut down di
5. 11 Parts List Parts List Ref No Part No Description 1 la 1b 3a 3c 3d 3e 3f 3g 3h 3j 3k 3l 3m 3n 6 7 SA 9A 104 A Replacement Danger and Warning labels tags and 77X011 77X012 77X535 77X536 100737 194868 16394 109114 15M442 104572 16V396 16V395 71X522 77X500 195341 16U728 15H108 KIT pump and vent valve includes 1a and 1b Dyna Star 60 models 77X100 see instruction manual 332514 KIT pump and vent valve includes 1a and 1b Dyna Star 90 models 77X101 see instruction manual 332514 PUMP VENT VALVE see instruction manual 332519 KIT reservoir 60 grease includes 3a 3n models 77X100 KIT reservoir 90 grease includes 3a 3n models 77X101 PLUG pipe NUT flanged hex SCREW cap flange head BREATHER GASKET cover PAIL reservoir 60 included in kit 77X535 PAIL reservoir 90 included in kit 77X536 COVER reservoir SCREW cap GASKET pump WASHER lock spring SEAL COVER KIT low level see instruction manual 332515 KIT plate follower 60 90 LABEL notice breather LABEL over pressurize warning LABEL pinch warning cards are available at no cost Cable Harness Kits all models Part No 717X527 77X528 717X529 24N402 12 Description KIT cable power series progressive system only Used with 77X528 KIT cable power extension 15 ft 4 6 m Used with 77X527 and 77
6. ANTABILITY 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 required that the present document as well as all documents notices and legal proceedings entered into gi
7. Instructions Repair and Parts G GRACO Dyna Star HP Pump System Provides lubricant flow and pressure to operate a single line parallel automatic lubrication system For automatic lubrication systems only Not approved for use in European explosive atmosphere locations Models 77X100 and 77X101 shown Important Safety Instructions E B Read all warnings and instructions in this man S ual and the Dyna Star HP and HF Pump instruction manual Save all instructions Maximum Working Pressure 3500 psi 24 1 MPa 241 bar Models All models include Tube in Tube design vent valve cover and tank System Low Follower Auto Fill Models Plate Shut Off Pound Pound 77x10 x X o 7x0 xx ff milo x mio x x milo xt x mo x xf x Can only be used with Low Level models CE PROVEN QUALITY LEADING TECHNOLOGY 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 where applicable FIRE AND EXPLOSION HAZARD When flammable fluids are present in the wor
8. X529 KIT cable power injector system only For use with 77X528 KIT cable 6 ft 1 8 m vent valve 2 pin For use with vent valve control Qty bh mb a O CO N aunt Ps et b mb mb mb 332540E Technical Data Maximum working pressure Pump wetted parts Vent valve wetted parts Reservoir wetted parts Reservoir overflow port size Reservoir fill port size Lubricant outlet port size Grease capacity Model 77X101 77X103 77X105 Model 77X100 77X102 77X104 Sound Data All pumps 332540E Technical Data 3500 psi 24 1 MPa 241 bar See Dyna Star HP and HF Pump manual 332514 See Dyna Star HP and HF Vent Valve Kit manual 332519 steel buna n rubber 1 2 inch npt 1 2 inch npt 3 8 npt f 90 Ib 41 kg 60 Ib 27 kg See Dyna Star HP and HF Pump manual 332514 13 Dimensions Dimensions se 45 ss ums 3683 Co mrna nohan 7 16 inch hole 6 13 7 8 inch bolt circle ma 60 Ib Models 90 Ib Models 14 332540E Notes 332540E Notes 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 period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco t
9. ifting aid secured to the pump lift ring See Technical Data in the pump instruction manual for pump weight Do not insert finger into the overflow port while filling a reservoir equipped with a follow plate Injury or 1 Mount Reservoir on sturdy flat surface Note loca amputation could result tion of Fill Port G and Lubricant Outlet Connection A for easy access once installed Priming 2 Connect High Pressure Lubricant Supply Line D to the Lubricant Outlet Connection A 1 After reservoir tank is completely filled remove high pressure lubricant supply line D from the outlet 3 Ground system see Grounding Mount reservoir to grounded chassis member 2 Connect power to pump f 3 Start pump and run pump until all air has been Pump Installation expelled and fluid flow is continuous Pump installation instructions are provided in the l l l Dyna Star HP or HF Pump instruction manual 332514 4 Reconnect the high pressure lubricant supply line provided with your system D to outlet 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 Auto Fill Shut Off The Auto Fill Shut Off is used refilling the grease tank
10. ing any compo nent can result in rupture fire explosion property damage and serious injury e Read and follow instructions supplied with each sys tem component e Reference letters used in the following Installation instructions refer to Typical Installation Key page 5 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 11 for a complete list of available kits Fuses 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 Operation Reservoir Installation Ope ration e Read and follow instructions supplied with each sys tem component EAN E a e Reference letters used in the following Installation Equipment is heavy To avoid injury instructions refer to Typical Installation Key page e Be sure unit is securely mounted before operation e Do not lift pressurized equipment e 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 l
11. ization can result in equipment rupture and serious injury e A pressure relief valve is required at each pump outlet e 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 manufacturers 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 Co
12. k 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 2 332540E Warnings PRESSURIZED EQUIPMENT HAZARD Over pressur
13. mply with all applicable safety regulations MOVING PARTS HAZARD Mg 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 332540E 3 Warnings BURN HAZARD z Equipment surfaces and fluid that s heated can become very hot during operation To 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 e Protective eyewear and hearing protection e Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturers 4 332540E Typical Installation Injector System 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 Controller Capabilities Low Reservoir Level Switch Level Indicator optiona Pressure Switch for System Control Remote Alarm Device Light or Horn
14. o 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 AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCH
15. sconnect power by turning off the ignition switch C Parts List 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 Ref No Part No Description Qty 1 77X011 KIT pump and vent valve 1 includes 1a and 1b Dyna Star 60 models 77X100 see instruc tion manual 332514 77X012 KIT pump and vent valve 1 includes 1a and 1b Dyna Star 90 models 77X101 see instruc tion manual 332514 la PUMP 1 1b VENT VALVE see instruction 1 manual 332519 3 77X535 KIT reservoir 60 grease 1 includes 3a 3n models 77X100 77X536 KIT reservoir 90 grease 1 includes 3a 3n models 77X101 3a PLUG pipe 2 3c NUT flanged hex 8 3d SCREW cap flange head 8 3e BREATHER 1 3f 194868 GASKET cover 1 3g PAIL reservoir 60 included in kit 77X535 PAIL reservoir 90 includedin 1 kit 77X536 3h 16V394 COVER reservoir 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 1 instruction manual 332515 77X530 KIT dip stick 90 grease see 1 instruction manual 332515 8 195341 LABEL notice breather 1 YA 160728 LABEL over pressurize warning 1 104 15H108 LABEL pinch warning 1 A Replacement Danger and Warning labels tags and cards are available at no cost 10 332540E Parts List Parts List
16. ven 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 procedures judiciaires ex cut s donn s ou intentes a la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information To place an order contact your Graco distributor or to identify the nearest distributor call 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 332540 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2013 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com June 2014
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