Graco 312350K User Manual

Instructions, Repair and Parts

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Model 247443 Shown

Dyna-Star

HYDRAULIC RECIPROCATOR AND PUMP

- Used for dispensing lubricating fluids only -

10:1 Ratio Universal Pump and Reciprocator

600 psi (4.1 MPa, 41 bar) Maximum Hydraulic Input Pressure 7500 psi (51 MPa, 517 bar) Maximum Fluid Outlet Pressure

Model 247540: Pump, 60 lb Automatic Lube Pump Module Length Model 247443: Pump, 120 lb Drum Length Model 247450: Pump, 400 lb Drum Length

Important Safety Instructions

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

312350K

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 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.

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.

• 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.

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 manufacturer’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.

• 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.

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Warnings

WARNING

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.

MOVING PARTS HAZARD

Moving parts can pinch, cut 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 and disconnect all power sources.

BURN HAZARD

Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe burns:

• Do not touch hot fluid or equipment.

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 MSDSs 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.

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:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

312350K 3

Installation

Maximum Working Pressure of Accessories

To reduce the risk of serious injury including fluid injection and splashing in the eyes or on the skin which may be caused if component ruptures, all accessories added to the reciprocator power supply side must have at least 600 psi (4.1 MPa, 41 bar) maximum working pressure.

All accessories added to the pump fluid outlet side must have at least 7500 psi (51 MPa, 517 bar) maximum working pressure.

Pump Accessories

NOTE: The reference letters in the following descrip-

tions, refer to the reference letters used in F

Follower Plate (A): Place follower plate on grease and rotate while pressing firmly to level material. Order part number 247700 for 60# and 90# automatic lube pump modules; 247701 for 120# refinery reservoir; or 247702 for 400# refinery reservoir.

IG. 2, page

Hydraulic Power Supply

See FIG. 2. page 6.

Limit Fluid Flow to Reciprocator

To reduce the risk of overpressurizing the hydraulic reciprocator which could cause a rupture and serious injury, including fluid injection, a hydraulic system must have a means to limit the incoming fluid flow to the reciprocator to a maximum of 3 gpm (11 lpm) and 600 psi (4.1 MPa, 41 bar). See description below.

The hydraulic power supply system (U) must have a pressure reducing valve and a pressure-compensated flow control. A flow control valve (Q) is required to limit the incoming flow to the reciprocator to a maximum of 3 gpm (11 lpm).

Hydraulic Lines

Shut-off Valves (H, L): Installed on the hydraulic supply

and return lines. Order Part No. 108537 and 112578.

Drain Line: Monitor the weepage of hydraulic fluid or lubricant. If it seems excessive or increases suddenly, the reciprocator/pump seals may need to be changed.

Pump Outlet Drain Valve (D): Helps relieve fluid pressure in pump when pump is shut off. Install valve close to pump fluid outlet. Order valve, Part No. 111229.

A pump outlet drain (D) is required in your system. This valve helps relieve pressure in the displacement pump and hose when shutting down system and in case of a clogged outlet hose. Install valve close to pump outlet.

Hoses: Use a minimum 1/2 inch supply line (R) and minimum 3/4 inch return line (F) on the reciprocator. Contact your Graco representative for line sizing.

Pressure Reducing Valve (N): Circulates excess hydraulic fluid pressure back to the hydraulic power supply. Install this valve (N) in the hydraulic supply line with a drain hose (W) teed into the hydraulic return line (F). Limit supply pressure to a maximum 600 psi (4.1 MPa, 41 bar).

Accumulator (P): Reduces hammering effect caused by the motor when it reverses direction.

Fluid-filled Pressure Gauge (M), Part No. 112567: Monitors hydraulic pressure to the reciprocator during startup. See F of the reciprocator. It can be removed after adjustment.

NOTE: Pressure gauge (M), pressure reducing valve (N) and a flow control valve (Q) are included in the Hydraulic Fluid Control Kit 247538 or 247705, which can be ordered separately.

IG. 2. Use the gauge for initial adjustment

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Installation

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Grounding

The equipment must be grounded to reduce the risk of static sparking. Static sparking can cause fumes to ignite or explode. Grounding provides an escape wire for the electric current.

• Pump: Order Grounding Wire and Clamp Kit,

Part No. 222011. See Grounding the Pump and F

IG. 1,

• Hydraulic Hoses and Fluid Outlet Hoses:

Use electrically conductive hoses only.

• Hydraulic Power Supply: Follow manufac-

turer’s recommendations.

• Flushing Pails: When flushing, only use metal,

grounded pails. Make firm, metal-to-metal contact between the metal part of the dispense valve and the pail. Use lowest possible pressure.

Grounding the Pump

Pressure Relief Procedure

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 spraying and before cleaning, checking, or servicing the equipment.

The system pressure must be manually relieved to prevent the system from starting or dispensing accidentally.

For the following instructions, see F

1. Shut off hydraulic power supply.

2. Close supply line shut-off valve (L).

3. Open dispensing valve to relieve pressure.

4. Open pump outlet drain valve. Have a container ready to catch drainage.

IG. 2.

To ground pump (See FIG. 1):

1. Remove ground screw (Z) and insert through eye of ring terminal at end of ground wire.

2. Fasten ground screw back onto pump and tighten securely.

3. Connect other end of wire to a true earth ground.

5. Close return line shut-off valve (H).

6. If you suspect the nozzle or hose is completely clogged or that pressure has not been fully relieved after following steps 1-5 above, very slowly loosen the hose end coupling to relieve pressure, then clear obstruction.

NOTE: Keep drain valve open until you are ready to dispense again.

FIG. 1

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Installation

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Typical Installation

The installation shown in FIG. 2 is only a guide for selecting and installing system components and accessories. Some of the equipment is required, as noted in the key. For assistance in designing a system to suit your needs, contact your Graco distributor.

Mount pump securely so it cannot move during operation.

FIG. 2

Key:

A Follower plate B Weep tube C Fluid outlet line (to gun) D Drain valve (required) E Ground wire F Hydraulic return line, minimum 3/4 inch I.D. (required) G Hydraulic outlet, 3/4” npt (f) H Return line shut-off valve, minimum 3/4 inch (required) J Hydraulic inlet, 3/4” npt (m) K Tee, 3/4” npt L Supply line shut-off valve (required)

*Included in Hydraulic Fluid Control Kit 247538 or 247705, which can be ordered separately.

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M *Pressure gauge N *Pressure reducing valve (required in systems over 600

psi [4.1 MPa, 41 bar])

lpm])

P Accumulator Q *Flow control valve (required in systems over 3 gpm [11

R Hydraulic supply line S Check valve T Variable volume pressure compensated pump U Hydraulic power supply V Drain line, accumulator

Operation

NOTICE

To prevent damage to pump, do not operate pump without it being securely mounted to a drum cover or support.

COMPONENT RUPTURE HAZARD

Overpressurizing any component can result in serious injury or property damage as a result of rupture, fire, and/or explosion.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 system:

• Be sure you know the maximum working pressure of

each component.

• Never exceed the maximum working pressure of the

lowest rated component in the system.

• Do not exceed the maximum pump cycle rate.

• The pump has a rated ratio of 10:1. However, it is

capable of reaching stall pressures equal to 12.5 times the hydraulic input pressure. To calculate the fluid output pressure, multiply the hydraulic pressure shown on the hydraulic control module gauge by 12.5.

For example:

600 psi hydraulic x 12.5 = 7500 psi fluid output

Starting Pump

For the following instructions, see FIG. 2.

1. Turn on hydraulic power supply.

2. Open return line shut-off valve (H) first, then slowly open the hydraulic supply shut-off valve (L).

3. Adjust flow control valve (Q) to limit the hydraulic flow to no more than 3 gpm (11 lpm), which is approximately 60 cycles per minute.

4. Adjust pressure reducing valve (N) to increase hydraulic inlet pressure from 50 to 600 psi (0.34 to

4.1 MPa, 3.4 to 41 bar).

• Increasing inlet pressure, increases outlet pres-

sure.

• Decreasing inlet pressure, decreases outlet

pressure.

5. Open drain valve while priming pump.

6. When pump is primed, close drain valve.

NOTICE

Always use lowest pressure possible to obtain desired results. This reduces pump wear.

4.14 MPa hydraulic x 12.5 = 51.8 MPa fluid output

41.4 bar hydraulic x 12.5 = 5.18 bar fluid output

• Regulate hydraulic pressure to the pump so that no

fluid line component or accessory is overpressurized.

Before Starting Pump

• Check hydraulic fluid level in hydraulic power supply before each use. Add fluid as necessary to fill the lines.

• Flush pump before using it for the first time to remove the light oil that was left in after factory testing to protect pump from corrosion. Be sure solvent used is compatible with the fluid to be pumped and the pump’s wetted parts. See Technical Data, page

26. Flush until clean solvent comes out of hose.

312350K 7

Maximum Working Pressures

To reduce the risk of serious injury, including fluid injection and splashing in the eyes or on the skin, which may be caused if a component ruptures:

• Never exceed 600 psi (4.1 MPa, 41 bar) Maximum

Hydraulic Pressure to the reciprocator.

• Never exceed 7500 psi (51 MPa, 517 bar) Maximum

Outlet Pressure from the displacement pump.

• Accessories added to the pump fluid outlet side should

have at least a 7500 psi (51 MPa, 517 bar) Maximum

Working Pressure.

• Read and understand COMPONENT RUPTURE

HAZARD instructions, page 7.

Shutdown

Relieve pressure, page 5, whenever you shutdown.

Troubleshooting

Problem Cause Solution

Pump does not run. Closed dispense valve. Pump only runs with valve open.

Pressure too low. Increase supply pressure using a

pressure adjusting valve.

Insufficient hydraulic fluid supply. Check hydraulic supply. Adjust to a

maximum of 3 gpm (11 lpm) flow.

Clogged fluid outlet line, intake valve, dispense valve, suction line.

Reciprocator damaged. Repair.

Pump speeds up or runs erratically. Pump piston and/or intake valve

worn.

Empty supply container. Refill and repair. Do not allow pump

Pump runs but output low on up and/or down stroke.

Pump run but output low on both up and down strokes.

Excessive weepage from weep tube (B), page 4.

Hydraulic oil leaks from fittings in the upper or lower reciprocator blocks (31, 32) [Parts page 23].

Pump piston and/or intake valve worn.

Insufficient hydraulic fluid supply. Check hydraulic supply. Adjust to

Pressure too low. Increase supply pressure using a

Clogged fluid outlet line, intake valve, dispense valve, suction line.

Worn throat packings. Repair.

Worn displacement seal. Repair.

Fittings 1, 5, 58, (Parts, page 23), are loose, or their o-rings are worn or damaged.

Relieve pressure, page 5. Check. Clear obstructions.

Relieve pressure, page 5. Check and repair.

to run dry. Monitor closely or use a low-level cutoff valve.

Relieve pressure, page 5. Check and repair.

maximum 3 gpm (11 lpm) flow.

pressure adjusting valve.

Relieve pressure, page 5. Check. Clear obstructions.

Tighten the self-sealing fittings. If leaking persists, change o-rings.

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Service

sealing fitting (1, 5, 60)

reciprocator

o-ring (1a, 5a,60a)

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36, 37

(hidden from view)

204

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107

Service

NOTE: The reference letters used in the following Ser-

vice instructions refer to the Typical Installation illustration provided on page 6.

The reference numbers used in the following Service instructions refer to the Parts pages beginning on page

23.

Pump Leaks at the Fluid Fittings

Tighten fittings (1, 5, 60; FIG. 3) which are self-sealing and have replaceable o-rings. If leaking persists, change o-rings.

Removing Displacement Pump from Reciprocator

Disassembly

FIG. 4

FIG. 3

1. Flush pump. Stop pump with displacement rod (35) (F

IG. 4) in the lowest possible position.

2. Relieve pressure, page 5.

Use of a hydraulic power supply with fluid temperatures above 154°F (68°C) can create hot surfaces which can burn if touched.

• Do not touch pump, motor, or if hydraulic system fluid is above 154°F (68°C).

• Allow sufficient time for pump and motor to cool before attempting any service or repair.

312350K 9

3. Disconnect fluid outlet hose (C) (F

IG. 2, page 6)

from displacement pump.

4. Slowly loosen hydraulic supply fitting (60) and return fitting (5) (F

IG. 4). Remove hoses.

5. Install plugs in tube fittings and hose ends.

6. Clamp reciprocator/pump assembly in a vise.

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