Graco 332514J User Manual

Instructions

®

Dyna-Star

HP and

332514J

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.

Models: Page 2

EN

Models

Models

Pump

Models

77X000 X X X

77X001 X X X X

77X002 X X X X

77X003 X X X X

77X011 X X X X X

77X012 X X X X X

77X013 X X X X X

77X014 X X X

77X015 X X X

77X016 X X X

Tube in

Tube

HP

Pump

HF

Pump

Vent

Valve

Compatible Reservoirs Maximum Working Pressure

35/60

Pound

90/120
Pound

400

Pound

3500 psi

24.1 MPa, 241 bar

5000 psi

34.47 MPa, 344 bar

2 332514J

Warnings

WARNINGWARNINGWARNING

WARNING

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.

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.

• 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.

332514J 3

Warnings

WARNINGWARNINGWARNING

WARNING

PRESSURIZED EQUIPMENT HAZARD

Over-pressurization can result in equipment rupture and serious injury.

• 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 prop­erty damage.

• Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material sup­plier 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 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.

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.

4 332514J

Warnings

WARNINGWARNINGWARNING

WARNING

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.

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 manufacturers.

332514J 5

Typical Installation: Injector System

E

D

C

F

B

H

K

G

FrontBack

Low Reservoir
Level Switch

(Level Indicator,

optional)

Pressure Switch
for System Control

Remote Alarm Device

(Light or Horn)

(user provided

Controller
Capabilities

J

K

L

A

M

Motor Control
Board

Pump Power

Pump Signal

Vent Valve

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.

FIG. 1

Key:

A Lubricant output connection
B Pump
C Ignition switch*
D High-pressure lubricant supply lines*
E Injector banks*
F Lubrication controller*
G Fill port (for reference only; non-tube-in-tube models only)
H Overflow port (for reference only)
J Breather (for reference only)

K Reservoir / Tank
L Vent Valve (for reference only)
M Motor

*User provided

6 332514J

Typical Installation: Series Progressive System

E

D

C

F

B

H

K

G

FrontBack

Low Reservoir
Level Switch

(Level Indicator,

optional)

Pressure Switch
for System Control

Remote Alarm Device

(Light or Horn)

(user provided

Controller
Capabilities

J

K

A

M

L

N

N

L

N

N

Motor Control
Board

Pump Power

Pump Signal

Typical Installation: Series Progressive System

The installation shown 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.

FIG. 2

Key:

A Lubricant output connection
B Pump
C Ignition switch*
D High-pressure lubricant supply lines*
E Primary metering device*
F Lubrication controller*
G Fill port (for reference only; non-tube-in-tube models only)
H Overflow port (for reference only)
J Breather (for reference only)
K Reservoir / Tank (for reference only)

L Secondary metering device
M Motor
N Bearing

*User provided

332514J 7

Installation

a

b

c

126

128

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; no more
lubricant or air is leaking from fitting as shown in F

IG. 3.

• 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 (F

IG. 5).

FIG. 3

Pump Module

Reference numbers used in the following instructions
refer to Parts, page 35. Upper case reference letters
used in the following instructions refer to Typical Instal­lation Drawings provided on pages 6 and 7.

NOTE:

• 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.

8 332514J

FIG. 5

3. Remove protective cap (d) from pump down-tube
(208) (F

IG. 6). Discard cap. You will not use it again.

208

d

c

e

e

e

FIG. 8

a

b

J

115

133

Installation

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 (F

IG. 7).

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 injuries, 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 cen­ter of the gasket and tank / reservoir cover and into
tank / reservoir.

6. Align holes in pump base with holes in tank / reser­voir cover (F

IG. 8). Securely fasten pump to tank /

reservoir cover using screws (a) and washers (b)
removed in Step 1, page 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 F

IG. 9.

FIG. 9

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.

7. Reinstall cover (126) using bolts (128). Use a
wrench to tighten bolts securely (F

IG. 10).

332514J 9

Wiring

126

128

0

D

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.

FIG. 10

8. Connect the timer/controller (F) (user supplied, if
used).

9. Connect High Pressure Lubricant Supply Line (D) to
the Lubricant Output Connection (0) (F
Vent Valve or Manifold.

NOTE: The High Pressure Lubricant Supply Line
(D) is disconnected from the Lubricant Output Con­nection (0) during Priming, page 15.

FIG. 11: Lubricant Outlet Connection

IG. 11) on the

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:

• 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 sys­tem. Graco recommends using 35A fuses.

10 332514J

Wiring

116

120

SR

119

115

CN

Installation Instructions

Reference numbers used in the following instructions
refer to Parts, page 36.

1. Remove screws (116), cover (120) and gasket (119)
to access motor lead wires (F

2. Feed the incoming power source wires through the
strain relief body (SR) and into the gear housing
(F

IG. 12).

a. Tighten the strain relief body (SR) to the gear

housing (115) to 5.1 ft.-lbs (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. spec­ifications to verify correct cable is used.

3. Make all source to input power connections (A and
B, page 13) and pump control connections (C and
D, page 13). Refer to F
wiring diagrams and Control Board diagram, page

13.

IG. 12).

IG. 13 or FIG. 14, page 12 for

4. Route wires into box. Replace gasket (119) cover
(120) and screws (116), being careful not to pinch
any wires. Tighten bolts securely. Torque bolts to
17-19 ft.-lbs (23-26 N.m).

FIG. 12

NOTICE

To avoid equipment damage, remove power before
switching modes from signal to power or power to sig­nal.

332514J 11

Wiring

35 A

18 - 32VDC

5 - 32VDC

Sig In

Sig In

SigPwr

Electric
Vent *
Valve

Motor Control Board

Lubrication

Controller

Pump Output

Pump Output

40A Relay

Sig In

Sig In

SigPwr

35 A

Pump Output

Pump Output

18 - 32VDC

5 - 32VDC

Electric
Vent *
Valve

Motor Control Board

Lubrication

Controller

24 VDC With Signal Input

FIG. 13: Pump control switch shown in signal mode

*A Vent Valve is only used in an injector-based system.

24 VDC With External Relay

FIG. 14: Pump controls switch shown in power mode

*A Vent Valve is only used in an injector-based system.

12 332514J

DC Models - Motor Control Board

MAX

MAX

MIN

MIN

SPEED

CURRENT

SIGPWR

BLUE

YELLOW

GREEN

HJ

A

B

C

D

F E

G

K

L

M

N

Wiring

FIG. 15

Key

A - (Negative) Power Input

B + (Positive) Power Input

C Turn On Signal 

D Turn On Signal +

E Red (Fault) LED - Blinks type of fault (See Fault Table)

F Green (Power) LED -

• Blinks: Power ON, Pump running

• Solid: Power/Pump OFF

G Current Control Potentiometer (Minimum: Turn Knob

Counter-Clockwise / Maximum: Turn Knob Clockwise)

H Flow Control Potentiometer (Minimum: Turn Knob

Counter-Clockwise / Maximum: Turn Knob Clockwise)

J Pump Control Switch*

• PWR - Turns pump on when power is applied

• SIG - Turns pump on when voltage is applied to:

- SIG IN 

K Blue Motor Wire Connection

L Yellow Motor Wire Connection

M Green Motor Wire Connection

N J5 Connector - Motor Hall Cable Connector

332514J 13

- SIG IN +

Fault Table: Red LED (E)

Fault Blinks

Over Current 1

Locked Rotor 2

Low or High Voltage 3

High Motor temp 4

Missing Temp Sensor 5

High Board Temp 6

Bad Hall Cable 7

*NOTE: Be sure power to pump is OFF before switching
between the PWR and SIG modes.

Wiring

2

30

23

20

10

4

40

30

in3/min.

2

30

23

10

5

2

20

15

in3/min.

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 HF Flow

15

8

Amps

HP Current HP Flow

15

8

Amps

14 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

Operation

COMPONENT RUPTURE HAZARD

The maximum working pressure of each component
in the system may not be the same. Over pressuriz­ing any component can result in rupture, fire, explo­sion, property damage and serious injury.

To reduce the risk of over pressurizing 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.

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. Reconnect 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.

Regulate pressure to the pump so that no fluid line,
component or accessory is over pressurized.

NOTICE

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.

332514J 15

Troubleshooting

Troubleshooting

Problem Cause Solution

Pump not powering ON, green LED
is not ON

Pump is powered on, green LED is
ON but pump is not cycling

Pump is powered on, green LED is
blinking, pump cycles continuously
instead of turning OFF

Pump is cycling but there is no
lubricant output from the outlet

Pump is cycling slow

Pump is cycling, there is output of
fluid at the outlet, pump pressure is
not building

Wiring not done correctly, polarity is
wrong or loose wire(s)

Fuse not in place or fuse is faulty Check fuse rating. If incorrect fuse is

Lubrication controller is in OFF mode Set lubrication controller to correct

Motor is not wired properly to control
board

Pump control switch (J) is set to
PWR mode. Pump cycling is not
controlled by signal output

Lubricant level in tank/reservoir is too
low

Damaged tank or reservoir Replace tank/reservoir.

Pump is cavitating

Pump seals are worn or damaged Replace pump seals. See Seal

Current Control Potentiometer Knob
(G) on motor control board is set too
low

Flow Control Potentiometer Knob (H)
on motor control board is set too low

Leakage in a lubrication line Check lubrication line for leakage.

Pump seals are worn or damaged Replace pump seals. See Seal

Check wire connections. Verify they
are all tight. Correct polarity.

used, install fuse of the correct
amperage.

lube cycle.
Connect wires to correct color

terminals.
Change pump control switch (J) to

signal mode (SIG).

Refill tank/reservoir.

Shake tank/reservoir to redistribute
grease.

Install a follower plate to help
distribute grease during pump
operation.

Replacement instructions, page 19.
Increase the current limit by turning

the Current Control Potentiometer
Knob (G), clockwise.

Increase the flow limit by turning the
Flow Control Potentiometer Knob
(H), clockwise.

Replace any lines that are leaking
and/or damaged.

Replacement instructions, page 19.

16 332514J

Troubleshooting

Problem Cause Solution

Red fault LED (E) on control board,
blinking

Over current fault - 1 blink System pressure too high Reduce system pressure by installing

larger diameter lubrication tubes

Current Control Potentiometer Knob
(G) on motor control board is set too
low

Increase the current limit by turning
the Current Control Potentiometer
Knob (G), clockwise.

System pressure too high Reduce system pressure by installing

larger diameter lubrication tubes

Current Control Potentiometer Knob
(G) on motor control board is set too
low

Increase the current limit by turning
the Current Control Potentiometer
Knob (G), clockwise.

Separate motor from pump and run

Motor is damaged

Locked rotor - 2 blinks

Pump lower is plugged

motor. If motor is damaged, replace
motor. See Motor Replacement
instructions, page 28.

Follow Seal Replacement instruc­tions 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
(G) on control board is set too low

Increase the current limit by turning
the Current Control Potentiometer
Knob (G), clockwise.

Separate motor from pump and run
Motor temperature is high - 4
blinks

Motor is damaged

motor. If motor is damaged, replace

motor. See Motor Replacement

instructions, page 28.

Motor control switch (J) is set to PWR
mode. Pump cycling is controlled by

Change motor control switch (J) to

signal mode (SIG).

signal output and pump is running
continuously

High duty cycle Reduce duty cycle.
Loose or damaged HALL sensor

cable

Missing temperature sensor ­blinks - 5 blinks

Motor is damaged

Verify HALL sensor cable is securely

attached. Tighten connection.

Replace damaged cable.

Separate motor from pump and run

motor. If motor is damaged, replace

motor. See Motor Replacement

instructions, page 28.

332514J 17

Troubleshooting

Problem Cause Solution

Control board temperature is
high - 6 blinks

Loose or damaged HALL sensor
cable - 7 blinks

Motor runs but pump does not

Control board LED’s blink erratically

System pressure too high Reduce system pressure by installing

larger diameter lubrication tubes.

Current Control Potentiometer Knob
(G) on control board is set too low

Increase the current limit by turning
the Current Control Potentiometer
Knob (G), clockwise.

Separate motor from pump and run

Motor is damaged

motor. If motor is damaged, replace
motor. See Motor Replacement
instructions, page 28.

Motor control switch (J) is set to PWR
mode. Pump cycling is not controlled

Change motor control switch (J) to

signal mode (SIG).
by signal output and pump is running
continuously

High duty cycle Reduce duty cycle.
HALL sensor cable not securely

attached

Verify HALL sensor cable is securely

attached. Tighten connection.
Damaged HALL sensor cable Replace motor.
Motor shaft/gears are stripped or

damaged

Gear box is damaged. Replace

pump.
Damaged control board Replace motor control board. See

Motor Control Board Replacement

instructions, page 31.

18 332514J

Repair

0

D

126

128

a

b

Repair

Seal Replacement

Kits 24T860 - HP Models or 24T861 - HF Models

• 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

1. Disconnect Dyna-Star pump from main power
source.

5. Loosen bolts (128) and remove cover (126) from
Dyna-Star pump (F

FIG. 17

6. Remove screws (a) and washers (b) holding
Dyna-Star Pump to cover and remove pump from
cover (F
table top protected with a drop cloth.

IG. 18). Place pump on a workbench or

IG. 17).

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) (F
the Vent Valve or Manifold.

FIG. 16: Lubricant Outlet Connection

IG. 11) on

FIG. 18

332514J 19

Repair

4

3

5

2

101

123

124

125

122

6

2

7. For Tube-In-Tube models only: Remove bolts (4)
holding tube (3) to pump adapter (2). Remove tube
and gasket (5) and set these parts aside to use for
reassembly (F

IG. 19).

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) (F

IG.

20).

e. Use a screw driver to turn motor shaft clockwise

until shovel piston (216) is seated in the lowest
position inside the shovel cylinder (208).

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. 21

f. Verify o-ring (122) is still in place and correctly

seated in motor (123) (F

IG. 20).

d. Remove motor.

FIG. 20

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 N.m) (F

9. Remove screws (6) from pump adapter (2) (F

IG. 20).

IG. 22).

FIG. 22

20 332514J

Repair

2

8

2

8

7

212

102a

102

212

8

2

9

8

10. Pull pump adapter (2) down to access retaining
spring (8) (F

IG. 23).

FIG. 23

11. Slide spring (8) out of groove (102a) in connecting
rod (102) to expose pump pin (7) (F

IG. 24). Push or

tap pump pin (7) out of hole.

12. Separate displacement rod (212) from connecting
rod (102) and separate these sections. Put section
(102) in a safe place. You will need it for reassem­bly. (F

IG. 25).

NOTE: Be careful when pulling these sections apart
that you do not lose spring (8).

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 (F

IG. 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 sec­tions. Separate the shovel cylinder section (208)
from the pump cylinder (204) first, using two pipe

332514J 21

Repair

208

216

215

204

211a

211

209

204

215

205

215

217

206

204

213

214

207

2

rod assembly

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 (F

V

IG. 27).

FIG. 27

16.

HP Pump: Use wrench on flats of priming rod (215)
and socket to loosen and remove shovel piston
(216) (F

IG. 27).

HF Pump:
a. Use wrench on flats of priming rod (215).

Remove hex nut (219).

b. Unscrew shovel (216) and remove it from prim-

ing rod (215).

18. Separate pump cylinder (204) from 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 (F

IG. 29).

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 direc­tion shown in F

IG. 30.

17. 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 cylin­der (204) (F

IG. 28). Discard o-ring. Use the new

o-ring included in the kit for reassembly.

FIG. 28

FIG. 30

22 332514J

21. Use a punch and hammer to tap out pins (217) hold-

215

217

213

214

217

212

201

2

2

202

212

ing the rod sections together (F

IG. 31). Use your

hands to unscrew shovel rod (215) and spacer rod
(212) from piston (213).

FIG. 31

Repair

FIG. 32

27. Use the displacement rod (212) to push the packing
u-cup (202) out of the pump adapter (2) in the direc­tion shown in F

IG. 33. Discard u-cup (202). A new

one is included in the kit.

22. Remove piston seal (214) from piston (213). Dis­card piston seal (214) and pins (217). New replace­ment parts are included in the kit.

23. 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.

24. Separate spacer cylinder (205) from pump adapter
(2) using a strap wrench to loosen cylinder. When
cylinder (205) is loose enough, use your hands to
unscrew and remove it from the pump.

25. Remove gasket seal (206) from inside pump
adapter (2) if it did not come out with the spacer cyl­inder (205). Discard gasket seal. Use gasket seal
included in the kit for reassembly.

26. Use a socket to loosen hex nut (201) and remove it
from the pump adapter (2) (F

IG. 32).

FIG. 33

332514J 23

Repair

2

202

lips
down

202

201

2

212

2

213

214

213a

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.

1. Apply a thin layer of grease to the packing u-cup
(202).

2. Use a flat, blunt-end tool to seat u-cup (202), with
the lips facing down, into the pump adapter (2) (F

34).

NOTE: Do not damage u-cup seal on threads during
installation.

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
and fluid leakage during operation.

IG.

FIG. 35

5. Slide together piston rod (213) and piston seal (214)
(FIG. 36).

FIG. 36

FIG. 34

3. Install hex nut (201) inside pump adapter (2). Use a
wrench to tighten nut securely (F

IG. 34). Torque to

18-22 ft lbs (24 - 30 N.m)

4. Apply a thin layer of grease to the surface of dis­placement rod (212). Slide rod into the pump
adapter (2) in the direction shown in F

IG. 35 only.

6. Thread piston rod (213) into end of displacement
rod (212). Hand tighten the two pieces together
securely, ending with hole (213a) (F
with hole (212a) (F

IG. 37).

IG. 36) aligned

24 332514J

Repair

212a

212

217

217

213b

215a

215

213

206

205

2

207

206

204

lips up

214

7. Install pin (217) through the aligned holes [(213a
(F

IG. 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; pre­venting pressure from building and causing fluid to
leak.

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) (F

IG. 38).

9. Install pin (217) through the aligned holes [215a and
213b (F

IG. 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; pre­venting pressure from building and causing fluid to
leak.

10. Apply a thin layer of grease around gasket (206).
Install gasket over end of spacer cylinder (205).
Slide cylinder over rod assembly as shown in F

IG.

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).

FIG. 39

11. Apply a thin layer grease to seal (206) and install
around pump cylinder (204) (F

IG. 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 F

IG. 40.

FIG. 38

FIG. 40

332514J 25

Repair

211

209

204

211a

208

216

215

204

9

2 212

8

212a

2a

8

2

212

7

102b

102

102a

15. Apply a thin layer of grease to o-ring (209) and
install around the seal retainer (211) (F

IG. 41).

16. Thread seal retainer (211) to pump cylinder (204)
with the seal end installed inside the pump cylinder
as shown in F

IG. 41. Use a wrench on the nut (211a)

to tighten adapter nut securely. Torque to 18-22 ft
lbs (24 - 30 N.m).

FIG. 41

HF Pump:

a. 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)
(F

IG. 42). Use a wrench to tighten securely.

18. Push displacement rod assembly up until displace­ment rod (212) is extending out the top of the pump
adapter (2) as shown in F

IG. 43.

19. Apply a thin layer of grease to gasket seals (9).
Install seals in pump adapter (2) as shown in F

IG. 43

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 (F

IG. 42). Torque to

145 to 155 in. lbs (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.

FIG. 42

FIG. 43

20. Place spring (8) over the end of displacement rod
(212) as shown in F

IG. 44.

26 332514J

FIG. 44

Repair

9

103b

103

2

6

2

pu

4

5

2

3

a

b

21. Remove pump assembly from vise. Align hole
(212a) in displacement rod (212) (F
necting rod hole (102b) (F

IG. 44). Insert pin (7)

IG. 43) with con-

through hole.

22. Slide spring (8) over pin (7) to secure pin in place.
Seat spring in groove (102a) in connecting rod (102)
to prevent it from moving during pump operation.

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 (F

IG. 45).

25. For Tube-In-Tube models only: Install gasket (5)
and Tube-In-Tube (3). Secure Tube-In-Tube to
pump adapter (2) using screws (4). Use a socket to
tighten bolts securely (F

IG. 47). Torque to 7-9 ft lbs

(9-12 N.m).

NOTE: Tube-In-Tube Replacement Kits 24T863 for
60 pound pumps, 24T864 for 90 pound pumps, and
24T865 for 400 pound pumps are available from
Graco. See Parts, page 38 for information about
ordering these kits or contact your Graco Distributor
or Graco Customer Service.

FIG. 47

26. Align holes in pump base with holes in tank / reser­voir cover. Securely fasten pump to tank / reservoir

FIG. 45

cover using screws (a) and washers (b) (F

IG. 48).

24. Secure pump adapter (2) to pump upper (pu) using
screws (6). Use a socket to tighten screws securely
(F

IG. 46). Torque to 7-9 ft lbs (9-12 N.m).

Be careful when installing pump to base that wire har-

NOTICE

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.

FIG. 46

332514J 27

FIG. 48

Repair

J

115

126

128

0

D

0

D

NOTE: When the pump is correctly installed, the
breather (J) will be below the control box (115) as
shown in F

IG. 49.

FIG. 49

27. Reinstall cover (126) using bolts (128). Use a
wrench to tighten bolts securely (F

IG. 50).

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

1. Disconnect Dyna-Star pump from main power
source.

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) (F

IG. 51) on the

Vent Valve or Manifold.

FIG. 51: Lubricant Outlet Connection

30. Connect power to pump.

31. See Operation instructions for pump priming and
reservoir filling instructions, page 15.

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) (F

IG. 52) on

the Vent Valve or Manifold.

FIG. 52: Lubricant Outlet Connection

28 332514J

Repair

116

120

119

134

117a

115

134

135

a

115

101

123

124

125

122

5. Remove screws (116) from motor control box cover
(120) and remove cover and gasket (119) (F

IG. 53).

FIG. 53

6. Remove nuts (134) as shown in F

IG. 54. Remove

washers (135) and motor wires from terminals.
Save these parts to use them for reassembly.

7. Disconnect sensor cable (117a) from motor control
board (F

IG. 54).

8. Use a wrench to loosen strain relief (a) and remove
wiring harness from housing (F

IG. 55).

FIG. 55

9. Remove screws (125) and washers (124) holding
motor (123) to gear box housing (101). Remove
motor. Verify o-ring (122) was removed with motor.
(F

IG. 56)

If o-ring (122) is still inside the gear box housing
(101), remove it.

Discard these parts in accordance with all safety
regulations.

FIG. 56

FIG. 54

332514J 29

Repair

101

123

124

125

122

115a

115

a

CN

SR

134

117a

115

134

135

Reassembly

NOTE:

• Use all new parts included in kit for reassembly.

1. Apply a thin coating of Gleitmo 585K grease to shaft
of the new motor.

2. Apply a thin layer of grease to o-ring (122). Install
o-ring in motor (123) (F

FIG. 57

3. Install new motor (123) using screws (125) and
washers (124) (F
screws securely. Torque to 17-19 ft lbs (23 - 25
N.m).

IG. 57).

IG. 57). Use a wrench to tighten

5. Match green, yellow and blue wires to terminals of
same color (written on the motor control board).
Secure wires to terminals using washers and nuts
(134 and 135) (F

IG. 59). Torque to 8-10 in. lbs (0.9 -

1.1 N.m).

4. Feed motor wire harness (a) through strain relief
opening (115a) in housing (115) (F

IG. 58).

Thread strain relief body (SR) into opening (115a).
Tighten to 3.5 ft.-lbs (4.7 N.m). Tighten coupling nut
(CN) to 2.0 ft.-lbs (2.7 N.m).

FIG. 59

6. Connect sensor cable (117a) (F

IG. 59).

7. Replace control board gasket (119) and cover (120)
with screws (116) being careful not to pinch any

FIG. 58

30 332514J

Repair

116

120

119

0

D

0

D

wires. Tighten screws securely. Torque to 17-19 ft
lbs (23 -25 N.m).

FIG. 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) (F
Vent Valve or Manifold.

IG. 61) on the

Motor Control Board Replacement: Kit 24T867

• 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

1. Disconnect Dyna-Star pump from main power
source.

FIG. 61: Lubricant Outlet Connection

10. Connect power to pump.

11. See Operation instructions for pump priming and
reservoir filling instructions, page 15.

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) (F
the Vent Valve or Manifold.

FIG. 62: Lubricant Outlet Connection

IG. 62) on

332514J 31

Repair

116

120

119

134

117a

115

134

135

A

B

C

D

117a

118

117

115

5. Remove screws (116) from motor control box cover
(120) and remove cover and gasket (119) (F

IG. 63).

FIG. 63

6. Remove nuts (134) as shown in F

IG. 64. Remove

washers (135) and motor wires from terminals.

7. Disconnect sensor cable (117a) from motor control
board (F

IG. 65).

8. Disconnect source to power input (A and B) and
pump control connections (C and D) (See F

IG. 65

and Control Panel, page 13).

FIG. 64

FIG. 65

9. Remove screws (118) securing motor control board
(117) to housing (115) (F

IG. 66).

FIG. 66

10. Remove motor control board from housing and dis­pose in accordance with all safety regulations.

32 332514J

Repair

118

117

115

A

B

C

D

134

117a

115

134

135

Reassembly

NOTE:

• Use all new parts included in kit for reassembly.

1. Install new motor control board (117) in housing
(115) using screws (118) (F
in. lbs (0.9 - 1.1 N.m).

IG. 67). Torque to 8 - 10

3. Match green, yellow and blue wires of motor to ter­minals of same color (written on the control board).
Secure wires to terminals using washers (135) and
nuts (134) (F

IG. 59). Torque to 8 - 10 in. lbs (0.9 -

1.1 N.m).

FIG. 67

2. Connect source to power input (A and B) and pump
signal connections (C and D) (F

IG. 65 and A,B,C,D,

page 13). Torque to 5.5 - 7 in. lbs (0.62 - 0.79 N.m).

FIG. 69

4. Connect sensor cable (117a) (F

IG. 69).

FIG. 68

332514J 33

Repair

116

120

119

0

D

5. Replace motor control board gasket (119) and cover
(120) with screws (116) (F

IG. 70) being careful not

to pinch any wires. Tighten screws securely. Torque
to 17 - 19 ft lbs (23 - 25 N.m).

FIG. 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) (F

IG. 71) on the

Vent Valve or Manifold.

FIG. 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

1

3

5

4

6

8

7

9

13

12

11

14

16

18

19

15

2

30

29

31/32

33

Main Assembly All Models

Parts List

Ref.
No. Part No. Description Qty

1 BOX, gear, model (page 36)
2 24T897 KIT, adapter, pump, HP models

24T898 KIT, adapter, pump, HF models

3  TUBE-IN-TUBE, 60#, includes 4,

model 77X001, 77X011

 TUBE-IN-TUBE, 120#, includes 4,

model 77X002, 77X012

 TUBE-IN-TUBE, 400#, includes 4,

model 77X003, 77X013

4  SCREW, shcs M6 x 25, models

77X001, 77X002 and 77X003

5  GASKET, fill tube flange, models

77X001, 77X002, 77X003, 77X011,

77X012, 77X013
6 SCREW, shcs, M6-1.0X90 SST
7 15F856 PIN, pump
8 119778 SPRING, retaining
9

†

11



12

@

13



@ SCREW, cap, models 77X011,

14 LABEL, name, serial
15

@

16 16V999 VALVE, pressure relief, 5000 psi

115122@VALVE, pressure relief, 4000 psi (27.6

18 77X540 KIT, vent valve, also includes 12, 13,

19 24T862 KIT, motor replacement

16U728 LABEL, safety, warning



29

15H108 LABEL, safety, pinch

30
31 = CABLE, gland
32 = O-RING, M25
33 ASSEMBLY, pump lower (see page

GASKET, seal

ADAPTER, outlet, models 77X000,

77X001, 77X002, 77X003, 77X014,

77X015, 77X016

O-RING, -014 FKM 75 Duro

SCREW, cap, models 77X000,

77X001, 77X002, 77X003, 77X014,

77X015, 77X016

77X012, 77X013, included in kit

77X540

PLUG, pipe

(34.47 MPa, 344 bar), models

77X000, 77X001, 77X002, 77X003,

MPa, 276 bar), models 77X011,

77X012, 77X013, 77X014, 77X015,

77X016

15, 16, 17; included with models

77X011, 77X012, 77X013 only. Can

be added to other models

37 and 38)

1
1
1
1

1

1

4

1

4
1
1
2
1

2
3

3

1
1

1

1

1

1
1
2
1
1
1

 Replacement Danger and Warning labels, tags, and cards

are available at no cost.

 Included in Tube-In-Tube Kit 24T863 (60 pound),
24T864 (90 pound), 24T865 (400 pound).

 Included in Seal Kit 24T860.
† Included in Seal Kit 24T861.

 Included in Outlet Manifold Kit 16X171.
@Included in Vent Valve Kit 77X540.
= Included in Cable Gland Kit 77X533.

332514J 35

Parts List

116

120

119

117

115

134

105

102

103

122

128

126

123

124

125

101

130

104

135

116

133

112

113

114

Gear Box

Ref.
No. Part No. Description Qty

101 HOUSING, gear box
102 ROD, connecting
103 BRACKET, gear box to pump
104 SCREW, M8
105 BOLT, M8
112 PACKING, o-ring
113 GEAR, first stage, w bearing
114 RING, retaining, internal
115 HOUSING, gear
116 $ SCREWS, M8
117  BOARD, control
118  SCREW, machine, phillips pan head
119 $ SEAL, control box cover
120 $ COVER, control box

1
1
1
2
2
1
1
1
1

11

1
4
1
1

122
123
124
125
126  COVER, shroud
128  BOLT, M6
133 RING, lift plate
134  NUT
135  WASHER

162841





PACKING, o-ring



MOTOR, 24VDC
WASHER, lock
SCREW, cap, hex head

 Included in Control Board Kit 24T867.
 Included in Shroud Kit 24T866.
 Included in Motor Kit 24T862

$ Included in Motor Control Board Seal Kit 24U827

NOTE: Kit 24U827 only includes quantity 4 - #116

Screws.

1
1
3
3
1

2
1
3
6

36 332514J

Parts List

HP Model Pump Lower: 16T857, 16N700, 16T757

Ref.
No. Part No. Description Qty

2 24T897 KIT, adapter, pump
201 15C530 NUT, retainer
202  PACKING, u-cup, throat, hp
204 15C537 CYLINDER, pump
205 16N718 CYLINDER, spacer, 35/60# (model

16T857)

16N686 CYLINDER, spacer, 90/120# (model

16N700)

16T753 CYLINDER, spacer, 400# (model

16T757)
206  GASKET, seal
207  SEAL, intake
208 192539 CYLINDER, shovel
209  O-RING
211  SEAL, retainer
212 16N719 ROD, displacement, 35/60# (model

16T857)

16N687 ROD, displacement, 90/120# (model

16N700)

16T754 ROD, displacement, 400# (model

16T757)
213 15G098 ROD, piston
214  SEAL, piston
215 15F296 ROD, shovel, 225, hp
216 16W249 PISTON, shovel, 50:1 hp
217  PIN, straight

 Included in Seal Kit 24T860.

1
1
1
1
1

1

1

2
1
1
1
1
1

1

1

1
1
1
1
2

HF Model Pump Lower: 16T706, 16T821, 16T822

Ref.
No. Part No. Description Qty

2 24T898 KIT, adapter, pump
201 16F947 NUT, retainer
202 † PACKING, u-cup
204 16F774 CYLINDER, pump
205 16T704 CYLINDER, 90/120#, spacer (model

16T706)

16T818 CYLINDER, spacer, 400# (model

16T821)

16T819 CYLINDER, spacer, 35/60# (model

16T822)
206 † GASKET
207 † SEAL, intake
208 16F775 CYLINDER, shovel
209 † O-RING
211 † SEAL, retainer
212 16T703 ROD, displacement, 90/120# (model

16T706)

16T810 ROD, displacement, 400# (model

16T821)

16T811 ROD, displacement, 35/60# (model

16T822)
213 16F771 ROD, piston, 50:1
214 † SEAL, piston
215 16F943 ROD, priming
216 16F944 PISTON, shovel, 50:1 hp
217 † PIN, straight
219 16C022 NUT, hex

† Included in Seal Kit 24T861.

1
1
1
1
1

1

1

2
1
1
1
1

1

1

1
1
1
1
2
1

332514J 37

Parts List

201

202

212

217

217

208

216

211

209

204

207

215

213

214

205

206

206

216

219

208

HF Models

HP Models

2

Pump Lower Parts Cable Harness Kits

Part No. Description

77X527 CABLE, power, series progressive system

only. Use with 77X528.

77X529 CABLE, power, injector system only. Use

with77X528.

77X528 CABLE, power, extension, 15 ft (4.6 m). Used

with 77X527 and 77X529

24N402 CABLE, 6 ft, vent valve, 2 pin for vent valve

control

77X533 KIT, cable, gland

Repair Kits

Part No. Description

24T860 KIT, seal, HP models
24T861 KIT, seal, HF models
24T862 KIT, motor replacement
24T863 KIT, tube-in-tube, 60 pound
24T864 KIT, tube-in-tube, 90 pound
24T865 KIT, tube-in-tube, 400 pound
24T866 KIT, shroud
24T867 KIT, control board replacement
24T897 KIT, adapter, pump, HP models
24T898 KIT, adapter, pump, HF models
24U827 KIT, motor control board seal

Accessories

Related

Part No. Description

77X522 Low Level and Dipstick 332515
77X511 Follower Plate, 120# tank / reservoir 312738
77X512 Follower Plate, 400# tank / reservoir 312738
77X514 Cover, 120# tank / reservoir 312738
77X515 Cover, 400# tank / reservoir 312738
77X500 Follower Plate - 60# Tank 332517
77X513 Mounting Bracket for 35# Bucket 332517
77X510 Follower Plate, 35# Bucket 332517
77X530 Dip Stick, 90# 332515
77X531 Dip Stick, 60# 332515
77X540 Vent Valve, pump mounted 332519
77X535 60 lb Tank 332540
77X536 90 lb Tank 332540
16X171 KIT, outlet manifold NA
16V999 VALVE, pressure relief, 5000 psi

(34.47 MPa, 344.7 bar)

115122 VALVE, pressure relief, 4000 psi

(27.6 MPa, 276 bar)

Manual

NA

NA

38 332514J

Technical Data

Dyna-Star HP or HF Lubrication Pump

US Metric

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 24VDC
Wire Terminal AWG Size for Control Board 24 to 10 AWG

Input Voltage Range

24 VDC 18 to 32 VDC

ON/OFF Signal Voltage Range and Current

Voltage Range 5 to 32 VDC
Drive Resistance 1.1K

Peak Operating Current

24 VDC 35A

Peak Power

24 VDC 720W

Pump Output

HF Models
HP Models

Weight - Pump Only

35 - 60 lb Tank / Reservoir 50 lb. 22.7 kg
90 - 120 lb Tank / Reservoir 55 lb. 25.0 kg
400 lb Tank / Reservoir 60 lb. 27.2 kg

Wetted Parts

Pump Wetted Parts steel, polyurethane, acetal, buna-N, aluminum,

Operating Temperature

HP Models -40° to 149°F -40° to 65°C

HF Models 14° to 149°F -10° to 65°C
Storage Temperature HP and HF Models -40° to 149°F -40° to 65°C
Humidity Level 90%
IP Rating IP69K
Audible Sound Pressure*

1000 psi (6.89 MPa, 58.95 bar) Models 70.7 dB(A)

2000 psi (13.79 MPa, 137.9 bar) Models 71.4 dB(A)

3000 psi (20.68 MPa, 206.84 bar) Models 71.4 dB(A)

4000 psi (27.58 MPa, 275.79 bar) Models 71.2 dB(A)

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.

See Performance Charts, beginning on page 41

polyester elastomer

9 - 16 cm

Technical Data

*Sound power was measured per ISO-9614-2.

332514J 39

Dimensions

C

A

B

D

E

Dimensions

C

60 Pound Models 90 lb Models 400 lb Models

Ref

A

B
C
D

E

US (inch) Metric (mm) US (inch) Metric (mm) US (inch) Metric (mm)

29 737 36.5 927 44.3 1125

16.8 427 16.8 427 16.8 427

10.6 268 10.6 268 10.6 268

11.0 279 11.0 279 11 279

11.1 283 11.1 283 11.1 283

40 332514J

Performance Charts

(655.48)

(573.55)

(491.61)

(409.68)

(327.74)

(245.81)

(163.87)

(81.94)

Dimensions

To find the Current (Amp) at a specified Flow Rate

3

/min.):

(in

1. Locate the specified Flow Rate on the vertical axis.

2. Follow the horizontal line to the intersection with the
System Operating Pressure.

3. Follow the vertical line down to determine the aver­age current required.

Graph 1: HF Model at Ambient Temperature

To find the Flow Rate (in

3

/min.) at a specified cur-

rent (Amp):

1. Locate the specified Current on the horizontal axis.

2. Follow the vertical line up to the intersection with the
System Operating Pressure.

3. Follow the horizontal line across to determine the
Flow Rate.

332514J 41

Dimensions

(573.55)

(491.61)

(409.98)

(327.74)

(245.81)

(81.94)

(163.87)

Graph 2: HF Model at 14°F (-10°C)

42 332514J

Graph 3: HP Model at Ambient Temperature

(327.74)

(294.97)

(262.19)

(229.42)

(196.64)

(163.87)

(131.10)

(98.32)

(65.55)

(32.77)

Dimensions

332514J 43

Dimensions

(229.42)

(32.77)

(65.55)

(98.32)

(131.10)

(163.87)

(196.64)

Graph 4: HP Model at -40°F (-40°C)

44 332514J

Notes

Notes

332514J 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 period 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, 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 required 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
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.

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: [phone] or Toll Free: 1-800-533-9655, Fax: [phone]

All written and visual data contained in this document reflects the latest product information available at the time of publication.

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.

Graco reserves the right to make changes at any time without notice.

For patent information, see www.graco.com/patents.

Original instructions. This manual contains English. MM 332514

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

February 2015