GRACO DYNA-STAR 2009845 (01) PDF DOCUMENT

The GRACO DYNA-STAR 2009845 has the following specifications and approvals:

Pump Model and Approvals

MODEL	DESCRIPTION	APPROVALS
2009845	Maximum Working Pressure: 6000 psi (41.3 MPa, 413 bar) 400 lb Drum Length	CE

Motor Approvals

APPROVAL MARK	COMPLIANCE
MET (E115803)	UL 1004-1 CSA C22.2 NO. 100

The safety symbols on the GRACO DYNA-STAR 2009845 have the following meanings:

SYMBOL	MEANING
Flame Icon	Burn Hazard
Lightning Bolt Icon	Electric Shock Hazard
Exclamation in Triangle with Person Icon	Equipment Misuse Hazard
Fire Icon	Fire and Explosion Hazard
Gears Icon	Moving Parts Hazard
Hand Injection Icon	Skin Injection Hazard
Splash Icon	Splash Hazard
Exclamation in Triangle	Safety Alert Symbol: Attention! Become Alert! Look for this symbol to indicate important safety messages.
Skull and Crossbones Icon	Toxic Fluid or Fumes Hazard
Hand near Outlet Icon	Do Not Place Hands or Other Body Parts Near Fluid Outlet
Hand Stopping Leak Icon	Do Not Stop Leaks with Hand, Body, Glove or Rag
Pressure Gauge Icon	Follow Pressure Relief Procedure
Ground Symbol	Ground Equipment
Person Reading Manual Icon	Read Manual
Person with Protective Gear Icon	Wear Personal Protective Equipment

Always read, understand, and follow these warnings before using the GRACO DYNA-STAR 2009845 to prevent serious injury.

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage can cause electric shock.

• Turn off and disconnect power cord before servicing equipment.

• Connect only to grounded electrical outlets.

• Use only 3-wire extension cords.

• Ensure ground prongs are intact on power and extension cords.

• Do not expose to rain. Store indoors.

• Only use an authorized service center to replace a damaged power cord.

SKIN INJECTION HAZARD

High-pressure fluid can pierce skin, which 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 servicing.

• Tighten all fluid connections before operating.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

FIRE AND EXPLOSION HAZARD

Flammable fumes from fluids like gasoline can ignite or explode.

• Use equipment only in a well-ventilated area.

• Eliminate all ignition sources (e.g., cigarettes, portable lamps).

• Ground all equipment in the work area.

• Keep the work area free of debris and flammable materials.

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

• Use only grounded hoses.

• Stop operation immediately if static sparking or a shock occurs.

• Keep a working fire extinguisher in the work area.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate when fatigued or under the influence.

• Do not exceed the maximum working pressure or temperature rating. See Technical Specifications.

• Use compatible fluids and solvents. Read manufacturer’s warnings and Safety Data Sheets (SDSs).

• Turn off all equipment and follow the Pressure Relief Procedure when not in use.

• Check equipment daily and replace damaged parts with genuine manufacturer’s parts only.

• Do not alter or modify equipment.

• Ensure all equipment is rated for the environment of use.

• Use equipment only for its intended purpose.

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

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

• Keep children and animals away from the work area.

MOVING PARTS HAZARD

Moving parts can pinch, cut, or amputate.

• Keep clear of moving parts.

• Do not operate with protective guards or covers removed.

• Follow the Pressure Relief Procedure and disconnect power before servicing.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids can cause serious injury or death.

• Read Safety Data Sheets (SDSs) for fluid hazards.

• Store and dispose of hazardous fluid according to applicable guidelines.

BURN HAZARD

Equipment surfaces and fluid can become very hot.

• Do not touch hot fluid or equipment.

PERSONAL PROTECTIVE EQUIPMENT (PPE)

Wear appropriate PPE to prevent injury.

• Protective eyewear and hearing protection.

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

Technical Specifications for Dyna-Star XT Electric Grease Pump

Specification	US	METRIC
Maximum Working Pressure	7000 psi	48.3 MPa, 483 bar
Maximum Recommended Pump Speed	30 cycles per minute
Maximum Fluid Temperature	180°F	82°C
Fluid Outlet	3/4 in. NPT
Stroke	4.75 in.	121 mm
Fluid Output	2.1 cu in. per cycle	34.4 cc per cycle
Wetted Parts	Steel, stainless steel, bronze, UHMWPE, aluminum, buna
Weight (400 lb Length)	118 lb	53.5 kg

Technical Specifications for Electric Motor

Specification	US	METRIC
Environmental Temperature Range	14°-104°F	-10°-40°C
IP Ratings, Ordinary Locations Models	IP66, Type 4X
IP Ratings, Explosive Atmospheres or Hazardous (Classified) Locations Models	IP66, Type 4X
Electrical Ratings	100-120 V, Single Phase, 50/60 Hz, 12 A
Maximum Branch Circuit Protection	20 A, Inverse Time Circuit Breaker
Short Circuit Current Rating	5 kA

Dimension Label	US	METRIC
A (thread)	3/4 in. NPT	N/A
B	63.63 in.	1616.2 mm
C	26.76 in.	679.7 mm
D	13.3 in.	337.8 mm
E (diameter)	2.125 in.	53.97 mm

The GRACO DYNA-STAR 2009845 motor is equipped with an I/O connector on the front of the motor cover for models in Ordinary Locations. All I/O connectors are capable of 30 VDC and are reverse-polarity protected. Wiring must be done by a qualified electrician.

Inputs and Outputs:

• One digital input: Use M12 cable pins 1 and 3 to enable/disable pump operation.

• One analog input: Use M12 cable pins 4 and 5 to control the pump set point (speed and pressure).

• One digital output: Use M12 cable pins 2 and 3 to control an external accessory (such as a lamp or LED).

I/O Connector Pinout (M12, 5-pin Connector)

PIN	CONNECTOR TYPE	DESCRIPTION
Pin 1 (Brown)	Digital Input	Has an internal 5 VDC pull-up for dry-contact or current-sinking circuits. Release or drive the input high to stop the equipment. Pull the input low to re-enable the equipment.
Pin 2 (White)	Digital Output (Equipment Running)	Current-sinking with a capacity up to 100 mA. Automatically pulled low when the equipment is running and released when not running.
Pin 3 (Blue)	GND/Common	Earth ground, common connection.
Pin 4 (Black)	Analog Input, Positive	4-20 mA current-controlled. When connected and driving current, this input disables the control knob (E) and controls the speed/pressure. The control knob can still be used to shut off the equipment (turn to 0). To re-enable equipment at the commanded speed/pressure, turn the knob up (clockwise).
Pin 5 (Gray)	Analog Input, Negative

To disable analog input control and enable the control knob (E):

1. Shut down the equipment. Ensure the LED is off.

2. Disconnect power to the system.

3. Disconnect the analog input (Pin 4, Pin 5).

4. Connect the unit to a power source to turn on the equipment and enable the control knob.

The LED indicator on your GRACO DYNA-STAR 2009845 shows the equipment’s status. If an error occurs, it will blink a set number of times corresponding to the error code. Always follow the Pressure Relief Procedure before investigating an error.

LED Indicator Lights Overview

LED INDICATOR	EQUIPMENT STATUS	NOTES
Red, solid	Powered on, speed set at 0 (zero), system not operating.	Be aware that the equipment is energized. To start, follow the “Start the Pump” procedure.
Yellow, solid	Calibrating. Performing startup sequence.	No action. Allow equipment to finish startup. Open the fluid drain or shutoff valve to allow cycling until startup is finished.
Green, solid	Startup sequence complete. Normal operation.	To start, follow the “Start the Pump” procedure. No action needed during normal operation.

LED INDICATOR	PROBLEM	CAUSE	SOLUTION
Red, flashing, one flash	Motor or controller overheating.	Hot operating environment or hot operating conditions.	Turn the control knob (E) to the off (0) position. Keep the system connected to power and allow it to cool. Inspect the fan; repair or replace as needed.
Red, flashing, two flashes	Motor current error.	Special-case cause.	Turn the control knob down, then back up. If the problem persists, contact Technical Support.
Red, flashing, three flashes	Voltage error or pump priming failure.	Input voltage is too high, too low, or too noisy, or an operational parameter was exceeded during priming.	Check line power voltage. Check control board connections.
Red, flashing, four flashes	Motor sensor error.	Motor sensor disconnected or not functioning.	Ensure the motor sensor cable is properly installed. If it is, replace the motor sensor.
Red, flashing, five flashes	Special-case problem.	Special-case cause.	Power cycle the unit. If the error persists, contact Technical Support.
Red, flashing, six flashes	Motor lead connection error.	One or more motor leads are connected incorrectly.	Check that all motor connections to the control board are correct.
Dim red, solid	Voltage detection error.	Power disconnected. System powering down.	Check power connection. Allow equipment to finish shutdown.
Green, flashing, continuous flash	Equipment stalled against pressure.	A valve downstream is closed or clogged. Or, a special-case cause.	Open the valve. Follow the Pressure Relief Procedure and clear the valve. Be aware the equipment is energized. For special cases, contact Technical Support.
No light (off)	Voltage detection error.	System not powered. Control failure.	Check power connection. Check the branch circuit for proper voltage. If unresolved, replace the control board.

KEY	COMPONENT	NOTES
A	Power Cord	Pigtail cord with plug
B	I/O Port	M12, 5-pin connector for On/Off Digital Input, Run Status Digital Output, and Speed/Pressure Control Analog Input.
C	LED Indicator	Indicates operational status and errors.
D	External Ground Fastener/Ground Symbol	Connection point for equipment grounding.
E	Control Knob	Standard: Enable/disable pump operation. Optional: Increase or decrease fluid flow rate.

The following provides a guide for a typical installation of the GRACO DYNA-STAR 2009845.

MOUNT THE PUMP

Mount the pump securely to prevent movement during operation, which could cause injury or damage.

• Select a convenient location with easy access to pump controls, room to change supply containers, and a secure mounting platform.

• To mount the pump directly onto a supply container, position it so the intake valve is no more than 1 in. (25 mm) from the bottom of the container. Mount the pump to the drum cover (C) or another suitable mounting device.

PUMP ACCESSORIES

To reduce the risk of serious injury from component ruptures, all accessories on the pump fluid outlet side must have a maximum working pressure of at least 7000 psi (48.2 MPa, 482 bar).

• Drain Valve (D) (required): Relieves fluid pressure in the pump.

• Shut Off Valve (E) (required): Isolates the pump from downstream fluid pressure.

• Fluid Pressure Gauge (F) (required): Monitors the fluid outlet pressure.

Other typical components include a Fluid Hose (A), Follower Plate (B), and Drum Cover (C).

The GRACO DYNA-STAR 2009845 stays pressurized until manually relieved. To prevent serious injury, follow this procedure when you stop operating and before cleaning, checking, or servicing the equipment.

1. Turn the fluid output control knob to off (0).

2. Disconnect power to the system.

3. Close the shutoff valve (E).

4. Open the drain valve (D).

5. Check the pressure gauge (F) to verify that the pressure has been relieved.

6. Leave the valves in these positions until the system is ready to be pressurized again.

Ensure the control knob is set to off (0) before connecting to a power source to prevent injury from splashing fluid.

PREPARE PUMP FOR STARTUP

1. Turn the control knob to off (0).

2. Check and tighten all fluid connections. Replace worn or damaged parts as needed.

3. Submerse the bottom of the pump in the fluid to be dispensed.

4. Make sure all fluid outlet valves are open.

5. If the fluid line has a dispensing device, hold the dispensing valve open into the end container.

6. Plug the power cord into a power source.

ADJUST OUTPUT

1. With the control knob turned off (0), turn on the power. The LED indicator will turn solid red. An alert beep sounds and the pump starts cycling if power is turned on while the control knob is not set to off (0).

2. Turn the control knob clockwise beyond (0) to enable the pump to cycle. A calibration sequence begins and the LED turns solid yellow.

3. After calibration, the pump starts pumping normally, and the LED light turns solid green.

4. The pump is factory-set to run at a constant speed. For speed adjustment, use the analog input (4-20mA) or reconfigure the control knob function.

You can configure the control knob on the GRACO DYNA-STAR 2009845 to either enable/disable the motor or to vary the fluid flow rate. This requires setting two switches inside the motor cover.

1. Verify the equipment is turned off and power is disconnected.

2. Remove the control cover.

3. Locate the Control Knob Function switch (CM-2) on the motor’s electrical board.

4. Select the Control Knob Function:

a. Enable/Disable Motor (default): Push switch CM-2 to the down position. Rotating the knob clockwise past (0) enables the motor; rotating to (0) disables it. In this mode, an I/O digital input is required to operate the pump. After selecting, proceed to step 7.

b. Variable Fluid Flow Rate: Push switch CM-2 to the up position. Rotating the knob clockwise (+) increases flow rate; counterclockwise (-) decreases flow rate.

5. If you selected variable flow rate, locate the Control Mode switch (CM-1).

6. Select the Control Mode:

a. Flow Control Mode (default): Push switch CM-1 to the down position. The control knob adjusts the fluid flow rate at the maximum operating pressure.

b. Pressure Control Mode: Push switch CM-1 to the up position. The control knob adjusts both the fluid flow rate and the stall pressure of the pump.

Note: If the Control Knob Function switch (CM-2) is in the enable/disable position, the Control Mode switch (CM-1) is ignored.

7. Reinstall the control cover.

Frequent or excessive cavitation can cause serious damage to your GRACO DYNA-STAR 2009845, including pitting and early wear of wetted parts. Cavitation is the formation and collapse of vapor-filled cavities in the fluid, which occurs when there is a pressure reduction at the pump inlet. This is more common with thick fluids.

To improve efficiency and reduce cavitation:

• Choose the optimal pump speed: Pumping too fast doesn’t allow enough time for fluid to enter the inlet side of the pump. This increases cavitation and reduces efficiency.

• Reduce fluid viscosity: Thinner fluids enter a pump inlet faster. Warm the fluid or dilute it (if appropriate for your application) to reduce its viscosity.

Always relieve pressure and clean the pump before storing the equipment for any length of time. Follow the Pressure Relief Procedure to ensure the system is depressurized and safe for storage.

At the end of the product’s useful life, dismantle and recycle the GRACO DYNA-STAR 2009845 in a responsible manner.

• Perform the Pressure Relief Procedure.

• Drain and dispose of fluids according to applicable regulations. Refer to the material manufacturer’s Safety Data Sheet.

• Remove motors, batteries, circuit boards, LCDs, and other electronic components. Recycle them according to applicable regulations.

• Do not dispose of electronic components with household or commercial waste.

• Deliver the remaining product to a recycling facility.

Before checking or repairing the GRACO DYNA-STAR 2009845, always follow the Pressure Relief Procedure. Check all possible problems and causes before disassembling.

PROBLEM	CAUSE	SOLUTION
Equipment emits beeping alert sound, LED light yellow	Pump is starting its automatic startup sequence. This happens if the pump is connected to power and the control knob is not in the off (0) position.	Turn the control knob to the off (0) position or disconnect power. If you intend to operate, allow the automatic startup sequence to complete.
LED light flashing	Equipment error, special-cause case.	See the LED Indicator Event Errors table for specific error codes and solutions.
Pump fails to operate or there is not fluid flow.	Closed dispense valve.	Open the valve.
	Clogged fluid lines, hoses, or dispense valve.	Disconnect the fluid line, then turn on the pump. If the pump starts, the lines are clogged. Clear the obstruction.
	Damaged motor.	Service the motor. Refer to the applicable procedures in the Repair section.
	Exhausted fluid supply.	Refill the fluid supply and prime the pump.
Erratic pump operation	Exhausted fluid supply.	Refill the fluid supply and prime the pump.
	Worn fluid seals.	Replace worn seals.
Pump operates but the output is low	Worn fluid seals.	Replace worn seals.
Fluid is coming out of the top of the pump outlet housing	Worn or damaged throat seal.	Replace worn seals.
Leaks at output pressure relief hole	Wrong style of fitting.	Replace with the correct fitting.
	Fitting is loose.	Tighten the fitting.
	Fitting is damaged.	Replace the fitting.
Equipment suddenly stops operating or shuts down	Ground fault interrupter (GFCI) tripped.	Remove controller from the GFCI circuit.
	Poor supply power.	Check connections. Determine and fix the source of the problem with the supply power.
	Exceeded operational parameters.	See the LED Indicator Event Errors table for specific error codes and solutions.

Before starting any repair, ensure the equipment is safe to work on. This equipment stays pressurized until manually relieved.

1. Follow the Pressure Relief Procedure when you stop operating and before cleaning, checking, or servicing the equipment.

2. Stop the pump while it is in the down stroke position.

3. Relieve all pressure by following the Pressure Relief Procedure again.

4. Turn the control knob to off (0). The LED light will turn solid red.

5. Disconnect power to the equipment. The LED light will turn off.

6. Disconnect the fluid hose.

7. Remove the shrouds (19) by loosening the screws (20).

8. Remove the tie rod nuts (12) and coupling (10), along with coupling collars (9).

9. Remove the motor assembly and shroud support (11).

SUPPLIES NEEDED:

• Socket wrench with 3/4 in., 1-7/16 in., 1-13/16 in., 1-15/16 in., and 2 in. sockets

• 15/16 in. open-end wrench

• Large adjustable wrenches

• Torque wrench (50-250 ft-lb)

• O-ring pick

• 2.5 in. spanner wrench

DISASSEMBLY STEPS:

1. Remove the pump lower from the container and place it on a workbench.

2. Position the pump lower horizontally in a vise, secured on its flats with the pressure relief hole facing up.

3. Use a 1-15/16 in. socket to loosen the inlet pump cylinder (113) to expose the hex on the connecting rod (107).

4. Use a 3/4 in. socket to loosen and unthread the shovel rod (112). Leave it inside the inlet pump cylinder (113) and set aside.

5. Use a 1-7/16 in. socket to loosen the seal retainer (109c), leaving it hand-tight in the pump cylinder (109).

6. Use a 1-13/16 in. socket to remove the pump cylinder (109).

7. Position a wrench on the displacement rod (101) flats and another on the fluid piston (103) flats. Loosen and remove the fluid piston (103).

8. Remove the check ball (104) from inside the displacement rod (101) and set it aside.

9. Remove the displacement rod.

10. Use a 2 in. socket to loosen and remove the throat seal retainer nut (108e).

11. Remove the outlet housing adapter (108b).

12. Remove the spacer (108f), throat seal (108d), throat seal back-up rings (108c), and O-ring (108j).

13. Remove the O-ring face seal (108h).

REASSEMBLY STEPS:

1. Replace the O-ring face seal (108h) and O-ring (108j) with new ones from the seal kit.

2. Replace the backup throat seal (108g) with a new one.

3. Replace the throat seal (108d) and throat seal backup rings (108c) with new parts. The chamfer on the seal backup rings must point away from the seal.

4. Replace spacer (108f). The step on the spacer must point toward the backup rings.

5. Reinstall the outlet housing adapter (108b), aligning the hole in the adapter with the pin (108a) on the outlet housing (108).

6. Use a 2 in. socket to reinstall the throat seal retainer nut (108e). Torque to 150-165 ft-lb (203.4-223.7 N·m).

7. Reinstall the displacement rod (101) through the outlet housing (108).

8. Reinstall the check ball (104) between the displacement rod (101) and the fluid piston (103).

9. Replace the piston seal retainer washer (102), piston seal (106), and piston seal backup rings (105) with new parts from the seal kit. The chamfer on the backup ring must point away from the seal. The piston seal has a green O-ring.

10. Reinstall the fluid piston (103) and connecting rod (107). Use a wrench on the displacement rod (101) flat and a 15/16 in. socket on the connecting rod (107). Torque to 140-160 ft-lb (189.8-216.9 N·m).

11. Replace the seals (109d), backup rings (109a), and seal (109b) in the pump cylinder (109) with new parts. The priming seal has a yellow O-ring and its backup rings have identification marks.

12. Replace the seal retainer (109c) and hand-tighten.

13. Apply anti-seize lubricant to the male threads of the pump cylinder (109) and reinstall it. Tighten with a 1-13/16 in. socket. Torque to 235-265 ft-lb (318.6-359.3 N·m).

14. Use a 1-7/16 in. socket to tighten the seal retainer (109c). Torque to 100-110 ft-lb (135.6-149.1 N·m).

15. Reinstall the inlet pump tube assembly. Connect the shovel rod (112) to the connecting rod (107) with a 3/4 in. socket. Torque to 50-60 ft-lb (67.8-81.3 N·m). Remove any grease from internal threads before installation.

16. Remove the pump from the vise.

1. Reinstall the pump lower in the grease container.

2. Reinstall the fluid hose.

3. Reinstall the coupling (10) and collars (9).

4. Remove the clevis pin (18) from the motor assembly.

5. Reinstall the shroud supports (11) and motor assembly. By hand, turn the ball screw of the motor to match the height of the displacement rod (101).

6. Reinstall the tie rod nuts (12) and torque to 50 ft-lb (67.79 N·m).

7. Reinstall the clevis pin (18).

8. Tighten the coupling (10) with a spanner wrench.

9. Reinstall the pump shrouds (19).

You will need a 10 mm socket wrench. All electrical wiring must be done by a qualified electrician.

REMOVE THE CONTROL COVER

1. Follow the procedure to “Prepare Equipment for Repair.”

2. Remove the fasteners (3) from the control cover (2).

3. Carefully tilt the control cover (2) away from the control board (15).

4. Disconnect all wires from the control cover to the control board. Hold the cover at a tilted angle while disconnecting wires to avoid damage.

5. Remove the control cover (2) from the stator housing (1).

6. Inspect for wear or damage and replace as needed.

INSTALL THE CONTROL COVER

1. Verify that power to the equipment is disconnected.

2. Install the gasket (35) into the groove on the stator housing (1). Ensure it is fully seated.

3. Hold the control cover (2) at an angle near the control board (15).

4. If a thermal pad is included, verify it is attached to the cover. If it has fallen off, place it on top of the capacitors before replacing the cover.

5. Connect wires from the control cover to the control board, ensuring they are connected to the correct locations as per the motor electrical schematics.

6. Align the control cover (2) to the stator housing (1).

7. Insert the fasteners (3) and tighten. Torque fasteners to 115 in-lb (13 N·m). Do not pinch wires when installing the cover.

8. Verify the control cover contacts the stator housing and the gasket does not show.

SUPPLIES:

• 10 mm socket wrench

• P2 (0.8 mm) Phillips screwdriver

• Thermal paste

• Screw extractor

• Fan press tool (available in kits)

REMOVE THE FAN ASSEMBLY

1. Prepare the equipment for repair.

2. Remove fasteners (3) from the fan guard (32) and remove the guard.

3. Remove the fan propeller (25) from the motor shaft (24d).

4. Remove the control cover.

5. Disconnect the fan cable (28b) and motor cable (24c) from the control board (15).

6. Remove fasteners (26) from the fan motor (24) assembly and remove the assembly.

7. Disassemble the fasteners (29), fan (28), mounts (27, 24b), and fan motor (24).

8. Inspect motor bearing (23) for wear. Only remove if replacing, using a screw extractor if necessary.

INSTALL THE FAN ASSEMBLY

1. Verify power is disconnected.

2. If the motor bearing (23) was removed, use the fan press tool (press bushing AA) to install the new bearing. Tap lightly; it will sit slightly raised from the stator housing surface.

3. Insert the fan propeller (25) into the holster (BB) part of the fan press tool.

4. Insert the fan propeller with holster into the stator housing (1), aligning the shaft hole.

5. Apply thermal paste to the contact surface between the fan motor (24) and stator housing (1).

6. Insert the fan rotor (24d) into position.

7. Insert the press bushing (AA) onto the fan motor shaft (24d) and lightly tap it to connect the shaft to the fan propeller. Ensure the shaft is completely pressed in. Do not use excessive force.

8. Remove the fan press tool.

9. Assemble the fan assembly (28), fasteners (29), and mounts (24a, 24b).

10. Apply thread sealant to fasteners (26).

11. Hold the fan assembly in place and install fasteners (26). Torque to 20 in-lb (2.3 N·m).

12. Connect the fan cable (28b) and fan motor cable (24c) to the control board (15). Use the provided tie to tuck wires away from pinch points.

13. Install the fan guard (32) and tighten fasteners (3).

14. Spin the fan propeller (25) by hand to ensure it turns freely.

15. Install the control cover.

SUPPLIES:

• 4 mm hex key wrench

• T15 Torx screwdriver

• 3 mm hex key wrench

• Dielectric grease

REMOVE THE MOTOR SENSOR BOARD

1. Prepare the equipment for repair.

2. Remove the fasteners (14) from the sensor-side stator cap (12).

3. Carefully remove the sensor-side stator cap (12) from the stator housing (1). Do not jolt it.

4. Disconnect the motor sensor cable (4a) from the motor sensor (4).

5. Remove the fasteners (5) from the motor sensor (4).

6. Remove the motor sensor (4) from the stator housing (1).

7. Inspect for wear or damage. Replace as needed.

INSTALL THE MOTOR SENSOR BOARD

1. Verify power is disconnected and all surfaces are clean.

2. Apply dielectric grease to the connector on the motor sensor cable (4a).

3. Connect the motor sensor cable (4a) to the new motor sensor (4).

4. Align the motor sensor (4) on the stator housing (1) and push until it clicks into place. Install fasteners (5) and torque to 20 in-lb (2.3 N·m).

5. Carefully install the sensor-side stator cap (12):

a. Align the pin (6) in the stator cap with the pin hole (6a) on the stator housing and gently insert the cap. Do not jolt the cap during installation.

b. Install the fasteners (14) into the cap. Torque to 110 in-lb (12 N·m).

6. Follow the procedure to “Recalibrate the Motor.”

REMOVE THE ROTOR

1. Prepare the equipment for repair.

2. Use preload nut installation tools to remove the preload nut (9) and hub (8) from the load-side stator cap (13).

3. Remove the load-side stator cap (13). Only remove components from this side.

4. On the sensor-side, turn the shaft (7a) until it protrudes from the load-side stator cap (12).

5. Use a wrench to hold the flat of the shaft (7a) in place. On the sensor-side, carefully tap the shaft to disengage the rotor and shaft assembly from the stator housing (1). Use a rubber mallet if needed.

6. Remove the rotor and shaft assembly (7, 7a) from the stator housing (1).

7. Remove seals (11) from the stator caps (12, 13) and seal (47) from the hub (8).

INSTALL THE ROTOR

1. Verify power is disconnected.

2. Install one seal (11) onto the stator cap (12) inside the stator housing.

3. Grease the tapered rotor bearings and insert the rotor and shaft assembly (7, 7a) into the stator housing. Ensure the flat of the shaft (7a) faces the sensor-side stator cap (13).

4. Install seal (47) on the hub (8) and assemble the other seal (11) to the hub.

5. Install the load-side stator cap (13) and torque fasteners (14) to 110 in-lb (12 N·m).

6. Apply anti-sieze to hub threads. Thread the preload hub (8) onto the load-side stator cap. Spin it until the seal (47) touches the cap bore.

7. Use a preload hub installation tool to torque the preload hub (8) to 20 ft-lb (27 N·m).

8. Temporarily install an M12 washer and bolt. Spin the rotor at least ten times to seat the bearings.

9. Remove the temporary bolt/washer. Loosen the preload hub (8) by one quarter rotation, then re-torque to 10 ft-lb (13 N·m). Do not overtighten.

10. Mark the location of the hub (8) relative to the stator cap (13).

11. Install the preload nut (9). Use a wrench to hold the hub (8) in place and torque the nut (9) to 50 ft-lb (68 N·m).

12. Verify the hub did not rotate from its marked location. Remove the installation tool.

13. Lubricate the rotor and shaft, then recalibrate the motor.

If the shaft (7a) was removed from the rotor (7), the rotor balls will fall out, and the rotor will not function. To avoid damage, you must re-ball the rotor.

1. Remove the rotor if you have not already done so.

2. Prepare a container to catch the loose rotor balls.

3. Rotate the shaft (7a) out of the sensor side of the rotor assembly (7) to remove the rotor balls as they fall out of the rotor ball inlet. Ensure all balls are removed.

4. Clean the grease from the shaft (7a) and the rotor assembly (7).

5. Thread the rotor assembly (7) onto the shaft (7a) until the thread lead-in is level with the rotor ball inlet.

6. Hold the assembled rotor and shaft about 30° up from horizontal, with the ball inlet at the lowest point.

7. Carefully drop the rotor balls one-by-one into the inlet inside the rotor (7).

8. Rotate the rotor (7) up and down the shaft (7a) to set the rotor balls into the shaft threads.

9. Follow the procedure to “Install the Rotor.”

Recalibrate the motor after installing a new control board, motor sensor, rotor, or re-torquing the preload hub and nut. Recalibrate after reassembling the motor module but before installing the pump components.

1. Turn the control knob (22) fully counter-clockwise (off).

2. Power up the motor module.

3. Turn the control knob (22) clockwise (on) to approximately 50% or higher. The rotor (7) will begin to spin and the LED (37) will turn yellow.

4. Wait for approximately 20 revolutions (10 seconds). The rotor will momentarily stop, then slowly spin one revolution, stop, reverse direction, and slowly spin one revolution again.

• Successful Calibration: The rotor (7) begins to spin and the LED (37) turns yellow.

• Unsuccessful Calibration: The rotor (7) stops spinning and the LED (37) flashes an error code (seven blinks). Ensure the rotor is not being restricted and is free to spin, then repeat this procedure.

5. Turn the control knob (22) fully counter-clockwise (off), and remove power.

6. Finish reassembling the pump.

For California residents, the following warning applies to the GRACO DYNA-STAR 2009845: WARNING Cancer and reproductive harm.