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Graco Dyna-Star XT Instruction Manual
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Graco Dyna-Star XT Instruction Manual

Graco Dyna-Star XT Instruction Manual

Electric grease pump
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I N S T R U C T I O N M A N U A L
MANUAL NUMBER X021555 | REVISION A | ENGLISH (US)
Dyna-Star® XT Electric Grease Pump
Provides lubricant flow and pressure to operate both single-line and series progressive automatic lubrication systems. For
automatic lubrication systems only. For professional use only. Not approved for use in explosive atmospheres or hazardous
(classified) locations.
Important Safety Instructions
Read all warnings and instructions in this manual before using the equipment. Be familiar with the
proper control and usage of the equipment. Save these instructions.
 
 
 
 
graco.com/contact
Model 2009845
Images are for illustrative purposes only
ti03057a

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Summary of Contents for Graco Dyna-Star XT

  • Page 1 Read all warnings and instructions in this manual before using the equipment. Be familiar with the proper control and usage of the equipment. Save these instructions.         ti03057a Model 2009845 Images are for illustrative purposes only graco.com/contact...

  • Page 2: Table Of Contents

    C O N T E N T S  Install the Control Board and Filter Board  Models and Approvals Assembly  Safety Symbols  Replace the Motor Sensor Board  General Warnings  Remove the Motor Sensor Board  Technical Specifications  Install the Motor Sensor Board  Dimensions  Repair the Center Section  I/O Pin Connection...

  • Page 3: Models And Approvals

    M O D E L S A N D A P P R O V A L S Table 1-1: Pump Models and Approvals MODEL DESCRIPTION APPROVALS 2009845 Maximum Working Pressure: 6000 psi (41.3 MPa, 413 bar) 400 lb Drum Length Table 1-2: Motor Approvals COMPLIES WITH UL 1004-1...

  • Page 4: Safety Symbols

    S A F E T Y S Y M B O L S The following safety symbols appear throughout this manual and on warning labels. Read the table below to understand what each symbol means. SYMBOL MEANING Table 2-1: Safety Symbols for Dyna-Star Electric Pump SYMBOL MEANING Toxic Fluid or Fumes Hazard...

  • Page 5: General Warnings

    G E N E R A L W A R N I N G S The following warnings apply throughout this manual. Read, understand, and follow the warnings before using this equipment. Failure to follow these warnings can result in serious injury.  ...
  • Page 6   G E N E R A L W A R N I N G S     WA RNI N G 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.

  • Page 7: Burn Hazard

      G E N E R A L W A R N I N G S     WA RNI N G MOVING PARTS HAZARD Moving parts can pinch, cut or amputate fingers and other body parts. • Keep clear of moving parts. •...

  • Page 8: Technical Specifications

    T E C H N I C A L S P E C I F I C A T I O N S Table 4-1: Technical Specifications for Dyna-Star XT Electric Table 4-2: Technical Specifications for Electric Motor Grease Pump   METRIC  ...

  • Page 9: Dimensions

    D I M E N S I O N S ti03059a Figure 5-1: Dimensions Diagram for Dyna-Star XT Electric Grease Pump Table 5-1: Dimensions for Dyna-Star XT Electric Grease Pump   METRIC A (thread) 3/4 in. NPT 63.63 in. 1616.2 mm 26.76 in.

  • Page 10: I/O Pin Connection

    I / O P I N C O N N E C T I O N The motor is equipped with the following inputs and   WA RN IN G outputs: • One digital input – use M12 cable pins 1 and 3 to  ...

  • Page 11: Connector Type

      I / O P I N C O N N E C T I O N   Table 6-1: I/O Connector Pinout (for Models in Ordinary Locations only) CONNECTOR TYPE DESCRIPTION Pin 1 Digital Input Digital input has an internal 5 VDC pull-up for dry-contact or current-sinking (Brown) circuits.

  • Page 12: Equivalent Electrical Circuits For I/O Pin Connection

    E Q U I V A L E N T E L E C T R I C A L C I R C U I T S F O R I / O P I N C O N N E C T I O N Table 7-1: Equivalent Electrical Circuits for I/O Pin I/O CIRCUIT EQUIVALENT CIRCUIT Connection (for Models in Ordinary Locations only)
  • Page 13   E Q U I V A L E N T E L E C T R I C A L C I R C U I T S F O R I / O P I N C O N N E C T I O N  ...

  • Page 14: Motor Electrical Schematics

    M O T O R E L E C T R I C A L S C H E M A T I C S Table 8-1: Key: Power Cord/Cable Schematics White Black - - - - - - L1/B - - - L2/N - - - Green (ground wire) Table 8-2: Key: General Electrical Schematics...

  • Page 15: Led Indicator Overview

    L E D I N D I C A T O R These sections provide an overview of the LED indicator lights and a list of error conditions and how to address them. L E D I N D I C A T O R O V E R V I E W Table 9-1: LED Indicator Lights LED INDICATOR EQUIPMENT STATUS...
  • Page 16   L E D I N D I C A T O R   Table 9-2: LED Indicator Event Errors PROBLEM CAUSE SOLUTION INDICATOR Red, flashing, Motor or controller Hot operating environment or hot Turn the control knob (E) to the off one flash overheating.
  • Page 17   L E D I N D I C A T O R   PROBLEM CAUSE SOLUTION INDICATOR No light (off) Voltage detection System not powered. Check power connection. error. Control failure. Check the branch circuit for proper voltage. Replace the control board. See Replace the Control Board and Filter Board Assembly, page X 0 2 1 5 5 5 | R e v i s i o n A...

  • Page 18: Component Identification

    C O M P O N E N T I D E N T I F I C A T I O N Table 10-1: Component Description COMPONENT NOTES Power Cord Pigtail cord with plug I/O Port M12, 5-pin connector On/Off Digital Input Run Status, Digital Output Speed/Pressure...

  • Page 19: Installation

    Typical Installation, page The installation shown is only a guide for selecting and installing system components and accessories. Contact   WA RN I N G your Graco distributor for assistance in designing a system to meet your needs.    ...

  • Page 20: Operation

    O P E R A T I O N Reference letters in the text, for example: (A), refer to 2. Check and tighten all of the fluid connections the callouts in Typical Installation, page before operating the equipment. P R E S S U R E R E L I E F P R O C E D U R E NOTE: Replace worn or damaged parts as needed.

  • Page 21: Configure The Control Knob Function

      O P E R A T I O N   C O N F I G U R E T H E C O N T R O L K N O B b. To select variable fluid flow rate, push the F U N C T I O N switch CM-2 to the up position.

  • Page 22: Tips To Reduce Cavitation

      O P E R A T I O N   b. For Pressure Control Mode, push the switch T I P S T O R E D U C E C A V I T A T I O N CM-1 to the up position.

  • Page 23: Recycling And Disposal

    R E C Y C L I N G A N D D I S P O S A L E N D O F P R O D U C T L I F E At the end of the product's useful life, dismantle and recycle it in a responsible manner.

  • Page 24: Troubleshooting

    T R O U B L E S H O O T I N G This section describes the problem, cause, and solution for Follow the Pressure Relief Procedure, page 20 before common issues with the product. checking or repairing the equipment. Check all possible problems and causes before  ...
  • Page 25   T R O U B L E S H O O T I N G   PROBLEM CAUSE SOLUTION Equipment suddenly stops operating Ground fault interrupter (GFCI) Remove controller from the GFCI or shuts down tripped circuit. Poor supply power Check connections.

  • Page 26: Repair

    R E P A I R 5. Disconnect the fluid hose.   W AR N I NG 6. Remove the shrouds (19). Leave screws (20) attached to the shrouds.         Reference numbers in the text, for example: (1), refer to the callouts in Parts, page 49 or the figures in the...
  • Page 27   R E P A I R   8. Remove the motor assembly and shroud support d. Before returning the pump to service, remove it (11). from the bracket stand. ti03816a Figure 15-4: Motor Assembly and Shroud Support 9. Optional: Mount the back of the pump (opposite side from the motor) to the maintenance bracket stand.

  • Page 28: Disassemble The Pump

      R E P A I R   D I S A S S E M B L E T H E P U M P 4. Use a 3/4 in. socket to loosen and unthread the shovel rod (112). Leave the shovel rod (112) inside S U P P L I E S of the inlet pump cylinder (113) and set aside.

  • Page 29: Torque Instructions

      R E P A I R   7. Position a wrench on the displacement rod (101) 10. Use a 2 in. socket to loosen and remove the throat flats and position another wrench on the fluid seal retainer nut (108e). piston (103) flats.

  • Page 30: Reassemble The Pump

      R E P A I R   R E A S S E M B L E T H E P U M P 4. Replace spacer (108f). 5. Reinstall the outlet housing adapter (108b) by S U P P L I E S aligning the hole in the adapter with the pin (108a) on the outlet housing (108).
  • Page 31   R E P A I R   8. Reinstall the check ball (104) between the 10. Reinstall the fluid piston (103) and the connecting displacement rod (101) and the fluid piston (103). rod (107) using one wrench on the displacement rod (101) flat and a 15/16 in.

  • Page 32: Reinstall The Motor

      R E P A I R   15. Use a 1-7/16 in. socket to tighten the seal retainer R E I N S T A L L T H E M O T O R (109c) to the pump cylinder (109) assembly, torque to 100–110 ft lb (135.6–149.1 N•m).

  • Page 33: Replace The Control Cover

      R E P A I R   R E P L A C E T H E C O N T R O L C O V E R Follow these procedures to remove and replace the control cover. SUPPLIES •...

  • Page 34: Remove The Control Cover

      R E P A I R   R E M O V E T H E C O N T R O L C O V E R c. Connect wires from the control cover (2) to the control board (15). 1.

  • Page 35: Replace The Power Cord/Cable

      R E P A I R   R E P L A C E T H E P O W E R C O R D / 6. Remove the cord/cable clamp (38b). C A B L E 7. Gently pull the power cord/cable (38) and wires out of the stator housing (1).

  • Page 36: Replace The Fan Assembly

      R E P A I R   R E P L A C E T H E F A N A S S E M B L Y 2. Remove the fasteners (3) from the fan guard (32). 3. Remove the fan guard (32) from the stator housing Follow these procedures to remove and install the fan (1).

  • Page 37: Install The Fan Assembly

      R E P A I R   I N S T A L L T H E F A N A S S E M B L Y d. Insert the fan propeller (25) with holster (BB) into the stator housing (1). Ensure the hole for 1.

  • Page 38: Replace The Control Knob Assembly

      R E P A I R   3. Assemble the fan assembly (28), fasteners (29), R E P L A C E T H E C O N T R O L K N O B and mounts (24a, 24b). A S S E M B L Y 4.

  • Page 39: Remove The Control Knob Assembly

      R E P A I R   R E M O V E T H E C O N T R O L K N O B 10. Install the control knob (22) onto the shaft (21c) on A S S E M B L Y the control cover (2).
  • Page 40   R E P A I R   R E M O V E T H E C O N T R O L B O A R D 6. If applicable, connect the filter board (18) power A N D F I L T E R B O A R D A S S E M B L Y brown cable to L1 and blue cable to L2 on the control board.

  • Page 41: Replace The Motor Sensor Board

      R E P A I R   R E P L A C E T H E M O T O R S E N S O R 3. Carefully remove the sensor-side stator cap (12) B O A R D from the stator housing (1).

  • Page 42: Repair The Center Section

      R E P A I R   R E P A I R T H E C E N T E R S E C T I O N 5. Remove the seals (11, 47) from the stator caps (12, 13).

  • Page 43: Repair The Rotor And Shaft Assembly

      R E P A I R   Table 15-1: Rotor and Shaft Assembly Notes R E P A I R T H E R O T O R A N D S H A F T A S S E M B L Y Face shaft flat toward the sensor-side stator cap Follow these procedures to repair the rotor and shaft (12).

  • Page 44: Remove The Rotor

      R E P A I R   R E M O V E T H E R O T O R 7. Remove the seals (11) from the stator caps (12, 13). 1. Follow Prepare Equipment for Repair, page NOTE: 2.

  • Page 45: Install The Rotor

      R E P A I R   I N S T A L L T H E R O T O R h. Use an applicable wrench on the preload hub installation tool to torque the preload hub (8) to 1.

  • Page 46: Re-Ball The Rotor

      R E P A I R   NO TICE 5. Thread rotor assembly (7) onto the shaft (7a) until the thread lead-in is level with the rotor ball inlet. To avoid equipment damage, ensure that the hub (8) does not rotate while torquing the nut (9).

  • Page 47: Lubricate The Rotor And Shaft

      R E P A I R   L U B R I C A T E T H E R O T O R A N D 3. Turn the rotor greasing tool into the center of the S H A F T rotor (7) until the shaft (7a) fully protrudes from the load-side stator cap (13).

  • Page 48: Recalibrate The Motor

      R E P A I R   5. Turn the control knob (22) fully counter-clockwise (off), and remove power. 6. Finish reassembling the pump. ti03994a Figure 15-47: Remove Rotor Greasing Tool 7. Use an applicable wrench to firmly hold the flat of the shaft (7a) in place.

  • Page 49: Parts

    P A R T S P U M P P A R T S An exploded-view parts diagram and parts list to identify and order replacement parts. 108e 109b 109a 108j 108g 108f 109c 109d 108d 108c 108b 108a 108h ti03594a Figure 16-1: Parts Diagram for Dyna-Star Electric Grease Pump X 0 2 1 5 5 5 | R e v i s i o n A...
  • Page 50   P A R T S   Table 16-1: Parts List for Dyna-Star Electric Grease Pump ITEM DESCRIPTION ITEM DESCRIPTION 108‡# – – – HOUSING, OUTLET 2010688 MODULE, 120V 108B# – – – ADAPTER, OUTLET – – – ROD, TIE, MOTOR 108C# –...
  • Page 51   P A R T S   – – – Not available separately or part number Included in Full Pump Lower Kit 2010555. varies. ‡ Included in Outlet Housing Kit 2009507. Included in Seal Kit 2009432. Replacement safety labels are available at ♦...

  • Page 52: Motor Parts

      P A R T S   M O T O R P A R T S An exploded-view parts diagram and parts list to identify and order replacement parts. Figure 16-2: Electric Motor Module X 0 2 1 5 5 5 | R e v i s i o n A  ...
  • Page 53   P A R T S   Table 16-2: Parts List for Electric Motor ITEM DESCRIPTION ITEM DESCRIPTION 18‡ – – – BOARD, assembly, line filter; FC2, FC4, FE2, 1‡ – – – STATOR FE4, FF2, FF4, FC8, FC9, 25V123 COVER, control FCA, FE8, FE9, FEA, FF8, FF9, FFA models 19C157...

  • Page 54: Item Description

      P A R T S   ITEM DESCRIPTION ITEM DESCRIPTION 103778 PLUG, 1/2 in. npt(f); – – – for models in North stainless steel America 20A460 BUSHING, strain relief – – – for models in EU – – – BUSHING, outer strain –...

  • Page 55: Kits And Accessories

      P A R T S   Table 16-6: Cord/Cable Kits K I T S A N D A C C E S S O R I E S MODEL KITS INCLUDE Parts kits are available (purchase separately). NUMBER P A R T K I T S 2009845 2010298 •...

  • Page 56: Accessory Kits

      P A R T S   Table 16-10: Motor Reseal Kit A C C E S S O R Y K I T S MODEL KITS INCLUDE Accessory kits are available (purchase separately). NUMBER Table 16-12: Accessories List for Dyna-Star Electric Grease Pump 2009845 2006210...

  • Page 57: California Residents

    C A L I F O R N I A P R O P O S I T I O N 6 5 CALIFORNIA RESIDENTS WARNING Cancer and reproductive harm — www.P65warnings.ca.gov. X 0 2 1 5 5 5 | R e v i s i o n A  ...
  • Page 58 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 manual is also suitable for:

2009845