Graco Dyna-Star 200:1 User manual

3A7519A

Instructions

Dyna-Star®200:1 and 

120:1 Grease Pumps

For dispensing grease in wellhead valve maintenance and wireline applications only. For

professional use only.

Dyna-Star 200:1

Model No.

25P785: 400 lb Drum Length

25P784: 120 lb. Drum Length

20,000 psi (137.9 MPa, 1379 bar) Maximum Working Pressure



100 psi (0.69 MPa, 6.89 bar) Maximum Air Pressure

Dyna-Star 120:1

Model No.

26A968: 400 lb Drum Length

26A967: 120 lb. Drum Length

12,000 psi (82.7 MPa, 827 bar) Maximum Working Pressure



100 psi (0.69 MPa, 6.89 bar) Maximum Air Pressure

Related Manuals

Important Safety Instructions

Read all warnings and instructions in this

manual before using the equipment. Save

these instructions.

Manual

(English) Description

3A7718 Dyna-Star®Air Motors

Contents

23A7519A

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation Instructions . . . . . . . . . . . . . . . . . . . . 6

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 8

Before Starting Pump. . . . . . . . . . . . . . . . . . . . . . 8

Priming and Pump Speed Adjustment . . . . . . . . . 9

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Suggested tools . . . . . . . . . . . . . . . . . . . . . . . . . 10

Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Reassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Recycling and Disposal . . . . . . . . . . . . . . . . . . . . . 18

End of Product Life . . . . . . . . . . . . . . . . . . . . . . 18

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Performance Charts . . . . . . . . . . . . . . . . . . . . . . . . 23

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Mounting Hole Layout . . . . . . . . . . . . . . . . . . . . 25

Technical Specifications . . . . . . . . . . . . . . . . . . . . 26

California Proposition 65 . . . . . . . . . . . . . . . . . . 27

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 28

Approvals

II 2 G Ex h IIA T4 Gb

NOTE: Type of Protection "h"

applied is constructional safety

"c".

Warnings

3A7519A 3

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The

exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks.

When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings.

Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this

manual where applicable.

WARNING

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.

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.

• Ground all equipment in the work area.

• 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.

• 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.

Warnings

43A7519A

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 Specifications in all equipment manuals.

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

Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For

complete information about your material, request Safety Data Sheets (SDSs) 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.

• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the

Pressure Relief Procedure and disconnect all power sources.

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 Safety Data Sheets (SDSs) 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.

BURN HAZARD

Equipment surfaces and fluid that is heated can become very hot during operation. To avoid 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. Protective equipment includes but is not

limited to:

• Protective eyewear, and hearing protection.

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

WARNING

Installation

3A7519A 5

Installation

Typical Installation

Pump Installation on Drum

Key:

A Grounded Air Line

B Air Filter (Graco P/N 106150)

C Air Regulator (required) (Graco P/N 244845)

D Air Line Oiler (Graco P/N 214849)

E Bleed-type Master Air Valve (required)

F Fluid Hose

H Ground Wire (required)

J Follower Plate

K Drum Cover

LAirMotor

M Drain Valve (required)

N Shut-off Valve (required)

P Pressure Gauge (required)

FIG. 1

Installation

63A7519A

Installation Instructions

NOTE: The reference letters in the following instructions

refer to Typical Installation, page 5.

Mounting the Pump

• Select a convenient installation location for the

equipment to ensure easy operator access to the

pump air controls, sufficient room to change supply

containers, and a secure mounting platform.

• For mounting the pump directly onto the supply

container, position the pump so that the intake valve

is no more than 1 in. (25 mm) from the bottom of the

container. Mount the pump to the drum cover (K) or

other suitable mounting device.

Pump Accessories

Drain Valve (M): used to relieve fluid pressure in the

pump.

Shut-off Valve (N): used to isolate the pump from

downstream fluid pressure.

Fluid Pressure Gauge (P): monitors the fluid outlet

pressure.

Air Line Accessories

Install the air line accessories (not supplied) as shown in

Typical Installation, page 5.

• Install a bleed-type master air valve (E) (required)

within easy reach of the pump, downstream from the

air regulator (C) (required).

• Install an air filter (B) (optional) to remove harmful

dirt and moisture from the compressed air supply.

For automatic air motor lubrication,

• Install an air line oiler (D) (optional) close to the

pump air inlet.

• Install an air regulator (C) (required) to control the

pump speed.

• Verify that the air hose is properly sized to deliver an

adequate supply of air to the motor. Refer to

Technical Specifications, page 26.

Mount the pump securely so that it cannot move

around during operation. Failure to do so could result

in personal injury or equipment damage.

Maximum Working Pressure of Accessories

To reduce the risk of serious injury including fluid

injection and splashing in the eyes or on the skin

which may be caused in component ruptures, all

accessories added to the pump fluid outlet side must

have the following maximum working pressures:

• Models 25P784 and 25P785: at least 20,000 psi

(137.9 MPa, 1379 bar) maximum working

pressure.

• Models 26A967 and 26A968: at least 12,000 psi

(82.7 MPa, 827 bar) maximum working pressure.

A bleed-type master air valve (E) is required to shut

off and relieve air pressure that may be trapped in the

air motor (L). Trapped air could cause the pump to

cycle unexpectedly and cause serious bodily injury,

including amputation.

Installation

3A7519A 7

Grounding

Pump: use ground wire and clamp (Graco P/N 222011,

not supplied), as shown in FIG. 2.

1. Connect the ground wire (Y) to the ground screw (Z)

located on the bottom of the air motor.

2. Connect the other end of the ground wire (Y) to a

true earth ground.

Air and fluid hoses: use only electrically conductive

hoses.

Air compressor: follow manufacturer’s

recommendations.

Solvent pails used when flushing: follow local code.

Use only conductive metal pails, placed on a grounded

surface. Do not place the pail on a nonconductive

surface, such as paper or cardboard, which interrupts

grounding continuity.

To maintain grounding continuity when flushing or

relieving pressure: hold metal part of the spray

gun/dispense valve firmly to the side of a grounded

metal pail, then trigger the gun/valve.

The equipment must be grounded to reduce the risk

of static sparking. Static sparking can cause fumes to

ignite or explode. Grounding provides an escape wire

for the electric current.

FIG. 2

Operation

83A7519A

Operation

NOTE: The reference letters in the following instructions

refer to Typical Installation, page 5.

Pressure Relief Procedure

1. Close the supply pump’s bleed-type master air valve

(E) (required in the system).

2. Close the shut off valve (N).

3. Open the pump drain valve (M).

4. Check the pressure gauge on the air regulator (C)

and the pressure gauge (P) to verify that pressure

has been relieved.

Before Starting Pump

NOTE: The reference letters in the following instructions

refer to Typical Installation, page 5.

This pump is designed to be used only in pumping

non-corrosive and non-abrasive lubricants. Any other

use of the pump can cause unsafe operating

conditions and component rupture, which can result in

fluid injection or other serious injury or fire or

explosion

This equipment stays pressurized until pressure is

manually relieved. To help prevent serious injury from

pressurized fluid, such as skin injection, splashing

fluid and moving parts, follow the Pressure Relief

Procedure when you stop spraying and before

cleaning, checking, or servicing the equipment.

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 input pressure.

• Use tubing, hoses, and other components with

pressure ratings equal lo or higher than the pump

rating.

• Do not exceed the maximum output pressure. For

example, the Dyna-Star 200:1 pump has a rated

ratio of 200:1. To calculate the fluid output

pressure, multiply the air pressure shown on the

pressure gauge of the air regulator (C) by 200.

100 psi air x 200 = 20,000 psi fluid output

0.69 MPa air x 200 = 137.9 MPa fluid output

• Do not exceed the maximum pump cycle rate.

• Use the required air regulator (C) to regulate air

pressure to the pump so that no fluid line

component or accessory is over pressurized.

Operation

3A7519A 9

Priming and Pump Speed

Adjustment

NOTE: The reference letters in the following instructions

refer to Typical Installation, page 5.

1. Open the bleed-type master air valve (E).

2. Open the drain valve (M), and slowly open the air

regulator (C) until the pump is running smoothly.

3. After all of the air is purged from the fluid hose,

close the drain valve (M).

4. Use the air regulator (C) to control the pump speed

and fluid pressure. Always use the lowest pressure

necessary to obtain the desired results.

5. The pump will start and stop as the shut-off valve

(N) is opened and closed.

6. If the pump accelerates quickly or is running too

fast, immediately stop the pump by closing the

bleed-type master air valve (E) and check the fluid

supply. If the supply container is empty and air has

been pumped into the lines:

a. Refill the supply container.

b. Prime the pump and fill the lines with fluid to

remove all of the air from the fluid lines.

NOTICE

Never allow the pump to run dry of the fluid being

pumped. A dry pump quickly accelerates to a high

speed and may cause damage to the pump seals.

Maintenance

10 3A7519A

Maintenance

Suggested tools

1/8 in. hex key

3/4 in. socket

15/16 in. socket

15/16 in. open-end wrench

1-7/16 in. socket

1-13/16 in. socket

1-15/16 in. socket

2 in. socket

socket extension

O-ring pick

Torque wrench (50 - 250 ft-lb/ 67.8 - 339 N•m)

Torque wrench (70 in-lb/ 7.9 N•m)

Large adjustable wrenches (1-1/4 in. jaw capacity)

Disassemble

1. Close the bleed type master air valve (E, FIG. 1) to

stall the pump while it is in the down stroke position

(FIG. 3).

2. Relieve pressure following the Pressure Relief

Procedure, page 8.

3. Disconnect the air supply hose from the pump air

motor (1).

4. Disconnect the fluid hose.

5. Remove the pump from the container and place on

a workbench.

6. Remove the muffler (27).

NOTE: Removing the muffler (27) allows easier

movement of the internal pump components to expose

the flats.

7. Remove the four screws (31) holding the mounting

flange (7) using 1/8 in. hex key (FIG. 5).

8. Remove the mounting flange (7), exposing the flats

(FIG. 5).

FIG. 3

FIG. 4

FIG. 5

Flat

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