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Instructions, Repair and Parts
®
Dyna-Star
312350E
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.
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Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama- tion 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
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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 b
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Installation Installation M K N Typical Installation of a L J H F G P Suction Feed System E Q D U C T R S B A ti0477a Key: A Follower plate M *Pressure gauge B Weep tube N *Pressure reducing valve (required in systems over 600 C Fluid outlet line (to gun) psi [4.1 MPa, 41 bar]) D Drain valve (required) P Accumulator E Ground wire Q *Flow control valve (required in systems over 3 gpm [11 F Hydraulic return line, minimum 3/4 inch I.D. (required) lpm]) G Hydraulic outlet, 3/4” npt (f) R Hydrauli
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Installation Pump Accessories Hydraulic Lines Follower Plate (A): ensures a good prime. Place Shut-off Valves (H, L): installed on the hydraulic supply follower plate on grease and rotate while pressing firmly and return lines. Order Part No. 108537 and 112578. to level material. Order part number 247700 for 60# and 90# automatic lube pump modules; 247701 for 120# Drain Line: Monitor the weepage of hydraulic fluid or refinery reservoir; or 247702 for 400# refinery reservoir. lubricant. If it
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Installation Grounding the Pump Grounding 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 To reduce the risk of static sparking, ground pump. securely. Check your local electrical code for detailed grounding instructions for your area and type of equipment. 3. Connect other end of wire to a true earth ground. � Pump: Use ground wire and clamp as shown in FIG. 3. Order G
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Operation Operation Pressure Relief Procedure Before Starting Pump COMPONENT RUPTURE HAZARD The system pressure must be manually relieved to Overpressurizing any component can result in prevent the system from starting or dispensing serious injury or property damage as a result of accidentally. Follow this pressure relief procedure rupture, fire, and/or explosion.The maximum working whenever you are instructed to: pressure of each component in the system may not be the same. To reduce the
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Operation Starting Pump If the Pump Leaks at the Fluid Fittings 1. Turn on hydraulic power supply. Tighten fittings (1, 5, 60) which are self-sealing and 2. Open return line shut-off valve (H) first, then slowly have replaceable o-rings. If leaking persists, change open the hydraulic supply shut-off valve (L). o-rings. 3. Adjust flow control valve (Q) to limit the hydraulic flow to no more than 3 gpm (11 lpm), which is sealing fitting (1, 5, 60) approximately 60 cycles per minute. 4. Adjus
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Troubleshooting Troubleshooting Problem Cause Solution Pump does not run. Closed dispense valve. Pump only runs with valve open. Pressure too low. Increase supply pressure using a pressure adjusting valve. Insufficient hydraulic fluid supply. Check hydraulic supply. Adjust to a maximum of 3 gpm (11 lpm) flow. Clogged fluid outlet line, intake valve, Relieve pressure, page 7. Check. dispense valve, suction line. Clear obstructions. Reciprocator damaged. Repair. Pump speeds up or runs erratical
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Service Service 32 35 Use of a hydraulic power supply with fluid tempera- tures above 154°F (68°C) can create hot surfaces which can burn if touched. � Do not touch pump, motor, or if hydraulic system fluid is above 154°F (68°C). 11 3 � Allow sufficient time for pump and motor to cool before attempting any service or repair. 1 44 Replacing Throat Seals See FIG. 5. 19 Replace throat seals if fluid leaks excessively 10 through the weep tube (B), page 4. This procedure can be done without d
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Service Disconnecting Reciprocator and Displacement Pump See FIG. 6 and Displacement Pump Parts, page 18. 1. Flush pump if possible and stop it with displacement rod in lowest position. 2. Relieve pressure, page 7. 60 3 3. Disconnect outlet hose from displacement pump. 36, 37 4. Slowly loosen hydraulic supply (60) and return (5) fittings to relieve any pressure. Then remove hoses. 5 5. Install plugs on tube fittings and in hose ends. 6. Check o-rings (5a and 60a) on fittings and replace the
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Reciprocator Repair Reciprocator Repair See FIG. 7 and FIG. 9 and Reciprocator Parts, page 18. Drain Oil Out of Reciprocator � Clean and inspect all parts for wear or damage. Before you begin, drain oil out of reciprocator. Replace worn parts as needed. For best results, always replace all the o-rings and seals 1. Relieve pressure, page 7. when you disassemble the pump. Repair Kit 2. Place reciprocator in a drain pan. 247455 is available. Parts included in the kit are marked with an asterisk
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Reciprocator Repair 6. Lay assembly on its side. Place a clean rag around 3, 39, 2 yoke (9) to prevent losing detent balls. Slide yoke (9) sideways off valve sleeve (29) while holding the 36, 37 balls (7) and spring (6) in place. 30 13* 7. Slide cylinder (25) off displacement rod (34). Hold 31 29 hex end of displacement rod in a vise and use a spanner wrench in pin holes of the piston (22) to 38 screw it off the rod. 26 2 51 6, 7 45 9 12 25 12 1 22 20 24* 34 23*, 49* 21 20 13* 32 17 20 21
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Reciprocator Repair 10. Clean all sealant from threads of any part you are See FIG. 10 for steps 13-16. ® ® reusing. Apply Loctite 242 or Perma-Loc 115 13. Lay Assembly A and Assembly B on work bench. thread sealant to first two or three internal threads of valve assembly (31). 14. Slide Assembly B in into center of tool (D), Part No. 189305. Align upper detent holes (C) of yoke (9) If you removed capscrew (51) apply thread sealant with center line of tool (D). to first two or three inter
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Reciprocator Repair When reinstalling cylinder (25), Step 19, be sure 3, 39, 2 port in valve spool (31) and port in the bottom 36, 37 cylinder cap (32) are in line with each other. Be sure o-rings (13*) are in place in valve spool and 13* cylinder cap. 31 19. Place cylinder (25) on cylinder cap (32). Install pis- ton (22) and valve assembly (31). 20. Install o-ring (49*) in deep, lower groove of piston (22). Install seal (23*) over o-ring. Install piston bearing (24*) around upper groove o
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Displacement Pump Repair Displacement Pump Repair 5. Use wrench to screw shovel (116) off of shovel rod Disassembly (108). See FIG. 13 for steps 1-10, except where noted. 6. Use strap wrench on pump cylinder (109) to screw it out of extension tube (114). Screw tube connector � Be sure you have all necessary parts on hand (113) out of pump cylinder. Remove bearing (111†) before you start. If using a repair kit, use all and seal (112†). parts in the kit for the best results. 7. Screw the sh
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Displacement Pump Repair 107 1 109 7 112† 111† 113 114 3 108 106† 110† 103 116 7 104† 106† 4 102 117 ti10608a ti10609a Assembled / Cutaway View 1 Using nut (113), torque the pump cylinder 109 to the extension tube (114) at 45 to 55 ft-lb (61 to 75 N.m). 3 Torque the shovel rod (108) to the piston (102) at 25 to 30 ft-lb (34 to 41 N.m). 4 Torque the piston (102) to the extension rod (107) at 25 to 30 ft-lb (34 to 41 N.m). 7 Assemble with lips facing up. FIG. 13 312350E 17
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Reciprocator Parts Reciprocator Parts 17 3 36 6 37 39 2 60 30 35 5 60a 4 31 5a 5 22 5 24 16 7 49 3 11 43 66 45 6 23 58 8 44 61 17 9 19 4 20 29 10 21 26 8 20 52 6 7 18 28 1 51 2 1a 27 4 12 15 1 6 46 38 34 5 13 32 ti10462a 71 1 Torque to 170-180 in-lbs (19-20 N.m) 14 2 Torque to 42-45 in-lbs (4-5 N.m). 25 3 Torque to 54-56 ft-lbs (73-76 N.m). 40 4 Torque to 54-56 in-lbs (6.0-6.5 N.m). 5 Torque to 40-48 ft-lbs (54-65 N.m) 6 Torque to 28-32 ft-lbs (38-43 N.m). 13 7 Assemble with lips facing up. 8 A
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Reciprocator Parts Reciprocator Parts Ref. Ref. No. Part No. Description Qty. No. Part No. Description Qty. 51 104092 CAPSCREW, sch; 10-24, 2 1 106470 ELBOW, straight thread, 3/4-16 1 unrc-3a x 5/8” unf-2a x 3/4-16 unf-2a, 37° flare 52 106115 LOCKWASHER, spring, 3/8” 4 includes item 1a 58 110064 PLUG, pipe, vented, 1/8-27 npt (f) 1 1a 110987 O-RING 1 60 107197 TEE, includes item 60a 1 2 178179 WASHER, sealing 1 60a 110987 O-RING 1 3 160276 CAPSCREW, hex hd, 3/8-24 x 5/8” 1 61 192653 VALVE, sp
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Pump Parts Pump Parts Model 247540 60# Automatic Lube Pump Module Length Ref No. Part No. Description Qty 201 RECIPROCATOR, page 18 1 202* 192533 SEAL, gasket 1 201 204 112154 PIN 1 205 DISPLACEMENT PUMP 1 206▲ 183741 LABEL, identification 1 Model 247443 206 120# Drum Length Ref No. Part No. Description Qty 201 RECIPROCATOR, page 18 1 202* 192533 SEAL, gasket 1 204 112154 PIN 1 202* 205 DISPLACEMENT PUMP 1 206▲ 183741 LABEL, identification 1 204 3 Model 247450 400# Drum Length 205 2 Ref No.
