Graco 247444, 247707, 247706, 247574 User Manual

Instructions, Repair and Parts

10:1 Dyna-Star Pump Module

Provides lubricant flow and pressure to operate a single line parallel automatic lubrication system. For automatic lubrication systems only.

Important Safety Instructions

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

Single Line Parallel Automatic Lubrication Systems

247444, 247574: Pump Module 243170: Hydraulic Vent Valve Kit 247538: Hydraulic Control Module Kit Custom Tank Installation Kit: 60#: 247970; 120#: 247456; 400#: 247457

3500 psi (24 MPa, 240 bar) Maximum Lubricant Outlet Pressure 3500 psi (24 MPa, 240 bar) Maximum Hydraulic Fluid Inlet Pressure 350 psi (2.4 MPa, 24.1 bar) Maximum Regulated Hydraulic Fluid Pressure

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ENG

Single Line Series Progressive Lubrication Systems

247706, 247707: Pump Module 247705: Hydraulic Control Module Kit for Remote Mounting with Standard Refinery Drums 247538: Hydraulic Control Module Kit

4500 psi (31 MPa,310 bar) Maximum Lubricant Outlet Pressure 3500 psi (14 MPa, 24.0 bar) Maximum Hydraulic Fluid Inlet Pressure 450 psi (3.1 MPa, 31.0 bar) Maximum Regulated Hydraulic Fluid Pressure

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Model 247444 Model 247574Model 247706 Model 247707

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.

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.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

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 forms from distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment.

• 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.

SKIN INJECTION HAZARD

High-pressure fluid from dispense valve, 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 dispense valve at anyone or at any part of the body.

• Do not put your hand over the end of the dispense nozzle.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

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Warnings

WARNING

PRESSURIZED EQUIPMENT HAZARD

Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

MOVING PARTS HAZARD

Moving parts can pinch 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 in this manual. Disconnect power or air supply.

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. Wait until equipment/fluid has cooled completely.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

• Always wear impervious gloves when spraying or cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

•Gloves

• Hearing protection

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Unpacking

The Dyna-Star pump module was carefully packaged for shipment by Graco. When the package arrives, perform the following procedure to unpack the units:

1. Inspect the shipping box carefully for shipping damage. Contact the carrier promptly if damage is discovered.

2. Unseal the box and inspect the contents carefully. There should not be any damaged parts.

3. Compare the packing slip against all items included in the box. Any shortages or other inspection problems should be reported immediately.

4. Store the box and packing materials in a safe place for future use. Graco recommends that all packing materials be saved in case the unit needs to be shipped again.

Pump Module Overview

Pump Module Operation

(See FIG. 4, page 8)

Cycles for Pump Modules 247444 and 247574 for injector-based, Automatic Lubrication Systems

1. Upon receiving a signal from a 24-volt Lubrication Controller (J), the 3-way Solenoid Valve (F) opens, starting the Pump (D) and closes the Vent Valve (U).

2. The pump builds pressure until the pressure switch in the system sends a signal to the Lubrication Controller (J), ending the cycle or Pump (D) stalls.

3. The Lubrication Controller (J) terminates the 24-volt signal to the 3-way Solenoid Valve (F).

4. The 3-way Solenoid Valve (F) closes, stopping the Pump (D) and opening the Vent Valve (U) into the Reservoir (P).

5. The Pressure Reducing Valve (S) and Flow Control Valve (N) control the pump output pressure and cycle rate.

Pump Module Capabilities

Pump Modules 247444 and 247574 for Injector-based, Automatic Lubrication Systems:

provide lubricant flow and pressure to operate a single line parallel automatic lubrication system. The module requires a hydraulic power supply and a timed signal from a lubrication controller. Based on these signals, the pump module provides lubricant flow and pressure to operate the injectors and vents the injector system to reset the injectors.

Pump Modules 247706 and 247707 for Single Line, Series Progressive-based, Automatic Lubrication Systems: provide lubricant flow and pressure to

operate a single line, series progressive, automatic lubrication system. The module requires a hydraulic power supply and a timed signal from a lubrication controller.

Cycles for Pump Modules 247706 and 247707 for Single Line, Series Progressive-based, Automatic Lubrication Systems

1. Upon receiving a signal from the 24-volt Lubrication Controller (J), the 3-way Solenoid Valve (F) opens; starting the Pump (D).

2. The Pump (D) provides lubricant flow and pressure until the Lubrication Controller (J) terminates the signal to the 3-way Solenoid Valve; stopping the Pump.

3. The Pressure Reducing Valve (S) and Flow Control Valve (N) control the pump output pressure and cycle rate.

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Pump Module Assembly

Models 247706 and 247707 only

Pump Module Assembly

For divider valve-based automatic lubrication systems.

(Unless otherwise indicated, see F

IG. 1).

Pressure Relief

Kit 247902

Hydraulic Control Module

1. Install Pump (D) on Reservoir (P).

2. Remove Vent Valve Hydraulic Control (J) fitting and replace with Plug (R) (F

IG. 6, page 9).

3. Install Hydraulic Control Module on Reservoir (P).

4. Connect Tank Line (G) to Pump (D).

5. Connect Pump High Pressure Hydraulic Line (H) to Pump (D).

6. Install Pressure Relief Kit (247902) to Pump Outlet.

7. Install model number label as shown in F

IG. 2.

IG. 1 Model 247706 shown

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Install Identification

Label Here

IG. 2

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Installation

Read instruction manual 312350 BEFORE installing this product.

• Be sure unit is securely mounted before operation.

• Do not lift pressurized equipment.

Grounding (for non-mobile installation)

(See FIG. 3 below)

CAUTION

The hydraulic supply must be 10µ filtered or better and supply 0.5 - 3.0 gpm (1.9 - 11.4 lpm) at 300 psi - 3500 psi (21 bar - 241 bar (2.1 MPa - 24 MPa).

1. Install Ball Valve (AA) (user provided) in the 3/8-inch High Pressure Hydraulic Line (X).

2. Connect the 3/8-inch High Pressure Hydraulic Line (X) to the High Pressure Hydraulic Connection swivel (Y).

3. Connect the 3/4-inch Hydraulic Tank Line (T) to the Tank Hydraulic Connection swivel (Z).

4. Connect the 24 VDC timer controlled signal to the 3-way Solenoid Valve (F).

1. Loosen grounding lug locknut (A) and washer (B).

2. Insert one end of a 12 gage (1.5 mm

) minimum ground wire (C) into slot in lug (D). Tighten locknut securely.

3. Connect other end of wire to true earth ground. To order a ground wire and clamp, order part number

222011.

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IG. 3

Pump Module

(See FIG. 4, page 8)

Mount Reservoir (P) on sturdy, flat surface with 6 (six), 3/8-inch diameter bolts. Note location of Fill Port (K), Hydraulic Lines (A) and Lubricant Outlet Connection (C) for easy access once installed.

5. Connect High Pressure Lubricant Supply Line (G) to the Lubricant Output Connection (C) for Single Line Parallel Systems or to Pressure Relief Kit Output Connection for Single Line, Series Progressive-based Systems.

6. Ground system (see GROUNDING). Mount Reservoir (P) to grounded chassis member.

Vent Valve Kit for Custom Tank Installation

(Unless otherwise indicated, see FIG. 5 and FIG. 6, page

1. Weld the bracket (F recommended configuration for mounting the vent valve. Paint the bracket if desired.

2. Connect the Hydraulic Control Line (A) to control module Vent Valve Hydraulic Control (J).

3. Connect Pump Output Connection line (C) to Pump outlet.

4. Connect the High Pressure Lubricant Supply Line (G, F

IG. 4, page 8) feeding the injector system to the

Lubricant Output (E).

5. Connect the Vent Line (F) to Custom Tank (user provided).

IG. 7, page 10) in place per

• The hydraulic system must be depressurized before connecting High Pressure Hydraulic Lines (A).

• Be sure Breather (M) is not plugged before filling Reservoir (P).

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Installation

Hydraulic Control Module for Custom Tank Installation

(Unless otherwise indicated, see FIG. 5 and FIG. 6, page

1. Mount control module on a flat, sturdy surface per the recommended configuration (Fig. 2, page 8).

2. Connect Pump Tank Line (G) to pump hydraulic outlet port.

3. Connect Vent Valve Hydraulic Control (J) connection to the hydraulic control line (A).

4. Connect the Pump High Pressure Hydraulic Line (H) to the pump hydraulic input port.

5. Connect high pressure hydraulic supply to the High Pressure Hydraulic Connection (L) and the tank lines to the Hydraulic Tank Connection (K).

6. Connect the 3-way Solenoid Valve (P) to the timer.

Coil should always be installed with lettering facing out.

Hydraulic Control Module 247705

(For Single-line, Progressive, Automatic Lubrication Systems with refinery reservoir installation)

(Unless otherwise indicated, see F

1. Mount control module on a flat, sturdy surface. The 6-foot hydraulic supply and hydraulic tank line must reach the pump when installed in the refinery reservoir.

2. Connect Pump Tank Line (G) to pump hydraulic outlet port.

3. Remove Vent Valve Hydraulic Control (J) and add plug (R) to vent port.

4. Connect the Pump High Pressure Hydraulic Line (H) to the pump hydraulic input port.

5. Connect high pressure hydraulic supply to the High Pressure Hydraulic Connection (L) and the tank lines to the Hydraulic Tank Connection (K).

IG. 5 and FIG. 6, page

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