Instructions, Repair and Parts
Models 77X100 and 77X101 shown
®
Dyna-Star
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.
Important Safety Instructions
Read all warnings and instructions in this man-
ual and the Dyna-Star HP and HF Pump
instruction manual. Save all instructions.
HP
332540E
EN
Maximum Working Pressure: 3500 psi (24.1 MPa, 241
bar)
Models:
All models include Tube-in-Tube design, vent valve,
cover and tank.
System
Models
77X100 X X
77X101 X X
77X102 X X
77X103 X X
77X104 X X X
77X105 X X X
*Can only be used with Low Level models.
35/60
Pound
Size
90/120
Pound
Dip
Stick
Low
Level
Follower
Plate*
Auto-Fill
Shut Off
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.
2 332540E
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.
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.
332540E 3
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.
4 332540E
Typical Installation: Injector System
E
D
C
F
B
H
K
G
Front
Back
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
N
P
R
S
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 outlet connection
B Pump
C Ignition switch*
D High-pressure lubricant supply lines*
E Injector banks*
M Motor
N Fluid overflow container
P Pump - remote filling station
R Reservoir - remote filling station
S Auto-Fill Shut Off
F Lubrication controller*
G Fill port (not used with Auto-Fill Shut Off)
H Overflow port (not used with Auto-Fill Shut Off)
*User provided
J Breather
K Reservoir
L Vent Valve
332540E 5
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)
† The pump outlet requires modification to convert an Injector-based
system to Series Progressive system. Dyna-Star HF and HP Outlet
Adapter Kits 77X543 rated 4000 psi (275.8 bar, 27.58 MPa) and
77X544 rated 5000 psi (344.7 bar, 34.47 MPa) are available from
Graco. Contact Graco Customer Service or your local Graco distributor to identify the correct kit for your installation location.
H Overflow port (for reference only)
J Breather (for reference only)
K Reservoir / Tank (for reference only)
L Secondary metering device
MMotor
N Bearing
*User provided
6 332540E
Installation
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
F
IG. 3.
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 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. Overpressurizing any component can result in rupture, fire, explosion, property
damage and serious injury.
• Read and follow instructions supplied with each sys-
tem component.
• Reference letters used in the following Installation
instructions, refer to Typical Installation Key, page
5.
Wiring
Grounding
FIG. 3
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 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.
332540E 7
Operation
Reservoir Installation
HEAVY EQUIPMENT HAZARD
Equipment is heavy. To avoid injury:
• Be sure unit is securely mounted before operation.
• Do not lift pressurized equipment.
• 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, in the pump
instruction manual for pump weight.
1. Mount Reservoir on sturdy, flat surface. Note location of Fill Port (G) and Lubricant Outlet Connection
(A) for easy access once installed.
2. Connect High Pressure Lubricant Supply Line (D) to
the Lubricant Outlet Connection (A).
3. Ground system (see Grounding). Mount reservoir
to grounded chassis member.
Operation
• Read and follow instructions supplied with each sys-
tem component.
• Reference letters used in the following Installation
instructions, refer to Typical Installation Key, page
5.
Start-up
Do not insert finger into the overflow port while filling
a reservoir equipped with a follow plate. Injury or
amputation could result.
Priming
1. After reservoir/tank is completely filled, remove high
pressure lubricant supply line (D) from the outlet.
2. Connect power to pump.
Pump Installation
Pump installation instructions are provided in the
Dyna-Star HP or HF Pump instruction manual 332514
provided with your system.
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 internally 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/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.
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.
8 332540E
Operation
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:
• 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).
Filling Reservoir With Auto-Fill Shut Off (S)
Refer to Auto-Fill Shut Off Kit instruction manual
332518.
Shutdown
For normal system shut down, disconnect power by
turning off the ignition switch (C).
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 9
Parts List
1a
1b
4
3e
3d
3h
3f
3k
3c
3a
3g
3j
3a
3d
3l
3m
3n
3c
8
9
10
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
1
1
1
1
1
2
8
8
1
1
1
1
4
1
4
1
1
1
1
1
1
1
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 instruc-
1a PUMP
1b VENT VALVE, see instruction
tion manual 332514
manual 332519
3 77X535 KIT, reservoir, 60# grease,
includes 3a-3n,
models 77X100
77X536 KIT, reservoir, 90# grease,
includes 3a-3n
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 77X536
3h 16V394 . COVER, reservoir
3j 109114 . SCREW, cap
3k 15M442 . GASKET, pump
3l 104572 . WASHER, lock, spring
3m 16V396 . SEAL
3n 16V395 . COVER
4 77X531 KIT, dip stick, 60#, grease, see
instruction manual 332515
77X530 KIT, dip stick, 90#, grease, see
instruction manual 332515
8
9
10
195341 LABEL, notice, breather
16U728 LABEL, over pressurize warning
15H108 LABEL, pinch warning
Replacement Danger and Warning labels, tags and
cards are available at no cost.
10 332540E
1a
1b
5a
3e
3h
5b
5e
3a
3g
3j
3a
3d
5f
3l
5c
5d
3f
3i
3c
3k
8
9
10
9
Parts List
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
77X012 KIT, pump and vent valve, includes 1a
1a PUMP
1b VENT VALVE, see instruction manual
3 77X535 KIT, reservoir, 60# grease, includes
77X536 KIT, reservoir, 90# grease, includes
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
3h 16V394 . COVER, reservoir
3i 104663 . PLUG, pipe
3j 109114 . SCREW, cap
3k 15M442 . GASKET, pump
3l 104572 . WASHER, lock, spring
5 77X521 VALVE, auto-fill shut off, see instruc-
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 x 2 mm 2
5f SEAL, auto shutoff valve 1
8 195341 LABEL, notice, breather
9 16U728 LABEL, over pressurize warning
10 16U727 LABEL, pinch warning
332514
and 1b, Dyna-Star 90#, models
77X101, see instruction manual
332514
332519
3a-3l,
models 77X100
3a-3l,
models 77X101
77X535
. PAIL, reservoir, 90#, included in kit
77X536
tion manual 332518
Replacement Danger and Warning labels, tags and
cards are available at no cost.
1
1
1
1
1
1
2
6
6
1
1
1
1
1
1
4
1
4
1
1
1
1
Parts List
332540E 11
Parts List
1a
1b
3e
3d
3h
3f
3k
3c
3a
3g
3j
3a
3d
3n
3l
3m
3c
6
7
10
9
8
Parts List
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
1a PUMP
1b VENT VALVE, see instruction manual
332519
3 77X535 KIT, reservoir, 60# grease, includes
77X536 KIT, reservoir, 90# grease, includes
3a 100737 . PLUG, pipe
3c . NUT, flanged, hex
3d . SCREW, cap, flange head
3e . BREATHER
3f 194868 . GASKET, cover
3g . PAIL, reservoir, 60#, included in kit
3h 16V394 . COVER, reservoir
3j 109114 . SCREW, cap
3k 15M442 . GASKET, pump
3l 104572 . WASHER, lock, spring
3m 16V396 . SEAL
3n 16V395 . COVER
6 77X522 KIT, low level, see instruction manual
7 77X500 KIT, plate, follower 60# / 90#
8
9
10
195341 LABEL, notice, breather
16U728 LABEL, over pressurize warning
15H108 LABEL, pinch warning
3a-3n, models 77X100
3a-3n, models 77X101
77X535
. PAIL, reservoir, 90#, included in kit
77X536
332515
Replacement Danger and Warning labels, tags and
cards are available at no cost.
Cable Harness Kits (all models)
1
1
1
1
1
1
2
8
8
1
1
1
1
1
4
1
4
1
1
1
1
1
1
1
Part No. Description
77X527 KIT, cable, power series progressive system only.
77X528 KIT, cable, power extension, 15 ft (4.6 m). Used with
77X529 KIT, cable, power injector system only. For use with
24N402 KIT, cable, 6 ft (1.8 m), vent valve, 2 pin. For use
12 332540E
Used with 77X528
77X527 and 77X529
77X528
with vent valve control.
Technical Data
Technical Data
Maximum working pressure 3500 psi (24.1 MPa, 241 bar
Pump wetted parts See Dyna-Star HP and HF Pump manual: 332514
Vent valve wetted parts See Dyna-Star HP and HF Vent Valve Kit manual: 332519
Reservoir wetted parts steel, buna-n rubber
Reservoir overflow port size 1/2 inch npt
Reservoir fill port size 1/2 inch npt
Lubricant outlet port size 3/8 npt (f)
Grease capacity
Model 77X101, 77X103, 77X105 90 lb. (41 kg)
Model 77X100, 77X102, 77X104 60 lb. (27 kg)
Sound Data: All pumps See Dyna-Star HP and HF Pump manual: 332514
332540E 13
Dimensions
A
B
C
D
E
F
G
Dimensions
60 lb Models 90 lb Models
Ref
A 30.5 77.47 38.0 96.52
B 14.5 36.83 14.5 36.83
C 1/2 inch npt 1/2 inch npt
D 1/2 inch-14 npt 1/2 inch-14 npt
E 14.5 36.83 14.5 36.83
F 19.4 49.28 27.0 36.83
G
14 332540E
US (inch) Metric (cm) US (inch) Metric (cm)
7/16 inch
Ø hole - 6; 13-7/8 inch bolt circle
Notes
Notes
332540E 15
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
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 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 332540
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
www.graco.com
June 2014
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