Hitachi 312350E User Manual

Instructions, Repair and Parts

Dyna-Star

HYDRAULIC RECIPROCATOR AND PUMP

- For 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.

Table of Contents

Warnings 2 Installation 4 Operation 7 Troubleshooting 9 Service 10 Reciprocator Parts 18 Pump Parts 20 Technical Data 21 Graco Standard Warranty 23 Graco Information 23

312350E

ti10604a

Model 247443 Shown

Warnings

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

WARNING

FIRE AND EXPLOSION HAZARD

When flammable fluids are present in the work area, such as gasoline and windshield wiper fluid, be aware that flammable fumes can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources, such as cigarettes and portable electric lamps.

• Keep work area free of debris, including rags and spilled or open containers of solvent and gasoline.

• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.

• Ground all equipment in the work area.

• Use only grounded hoses.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment

until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all

equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS forms from distributor or retailer.

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

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

SKIN INJECTION HAZARD

High-pressure fluid from dispense valve, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical

treatment.

• Do not point dispense valve at anyone or at any part of the body.

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

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

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

2 312350E

Warnings

WARNING

MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,

follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.

TOXIC FLUID OR FUMES HAZARD

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

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

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

• Always wear impervious gloves when spraying or cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENT

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

• Protective eyewear

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

•Gloves

• Hearing protection

312350E 3

Installation

Typical Installation of a Suction Feed System

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)

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

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

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

psi [4.1 MPa, 41 bar])

lpm])

ti0477a

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

FIG. 1

Although the installation shown in F

IG. 1 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 to suit the type of installation planned.

Maximum Working Pressure of Accessories

To reduce the risk of serious injury including fluid injection and splashing in the eyes or on the skin

CAUTION

Do not operate pump without it being securely mounted to a drum cover or support.

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.

4 312350E

Installation

Pump Accessories

Follower Plate (A): ensures a good prime. 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.

Pump Outlet Drain Valve

• 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.

• Mount pump securely so it cannot move around during operation. Failure to do so could result in personal injury and/or equipment damage.

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.

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. See F

IG. 2.

ti10602a

Hydraulic Power Supply

See FIG. 1.

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).

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

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 details of 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.

IG. 1. Use the gauge for initial adjustment

312350E 5

Installation

Grounding

To reduce the risk of static sparking, ground pump. Check your local electrical code for detailed grounding instructions for your area and type of equipment.

• Pump: Use ground wire and clamp as shown in

IG. 3. Order Grounding Wire and Clamp Kit,

Part No. 222011.

• 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

To ground pump (See FIG. 3):

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.

ti10603a

IG. 3

6 312350E

Operation

Pressure Relief Procedure

The system pressure must be manually relieved to prevent the system from starting or dispensing accidentally. Follow this pressure relief procedure whenever you are instructed to:

• relieve pressure.

• check or service any system equipment.

• install or clean nozzle.

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.

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

IG. 1.

Before Starting Pump

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:

Leave drain valve open until you are ready to dispense again.

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.

600 psi hydraulic x 12.5 = 7500 psi fluid output

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.

• 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

20. Flush until clean solvent comes out of hose.

312350E 7

Operation

Starting Pump

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.

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

If the Pump Leaks at the Fluid Fittings

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

sealing fitting (1, 5, 60)

reciprocator

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

ti04478

IG. 4

Shutdown

Relieve pressure, page 7, whenever you shutdown.

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) Maxi- mum Hydraulic Pressure to the reciprocator.

• Never exceed 7500 psi (51 MPa, 517 bar) Maxi- mum 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.

8 312350E

+ 16 hidden pages