Graco Compact Dyna-Star Instructions Manual Download Page 2

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Contents

3A6941B

Contents

Pump Model Selection Matrix...................................... 3

Warnings ..................................................................... 4

Installation ................................................................... 6

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 6

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Series Parallel System ................................... 7

Series Progressive System ............................ 7

Inlet and Outlet Components . . . . . . . . . . . . . . . . 7

Vent Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . 8

Motor Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Typical Installation: Series Parallel System . . . . . 9

Typical Installation: Series Progressive System 10

Typical Wiring: Series Parallel Systems. . . . . . . 11

Component Identification . . . . . . . . . . . . . . . . . . 12

Setup ......................................................................... 13

Fill the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Fill Pumps with an Auto-Fill Shut Off (AFSO) . . 15

Refill the Tank: Pumps with an Auto-fill

Shut Off (AFSO)..................................... 16

Fill Pumps Without an Auto-fill Shut Off (AFSO) 18

Refill the Tank: Pumps without an Auto-fill

Shut Off .................................................. 18

Operation................................................................... 20

Priming the System . . . . . . . . . . . . . . . . . . . . . . 20

Pump Operation Overview . . . . . . . . . . . . . . . . . 20

Series Parallel System ................................. 20

Series Progressive System .......................... 20

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Level Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . 21

Low Level Switch.......................................... 21

Level Transducer.......................................... 22

Pressure Switch............................................ 23

Pressure Transducer .................................... 23

Maintenance ............................................................. 24

Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Reassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Troubleshooting ........................................................ 38

Parts.......................................................................... 41

Related Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Dimensions: Pump with Tank ................................... 45

Dim ensions: Stand Alone Pump ............................... 46

Dimensions: Stand Alone Pump ............................... 47

Mounting Dimensions: Stand Alone Pump ............... 48

Notes:........................................................................ 49

Technical Specifications ........................................... 50

California Proposition 65 . . . . . . . . . . . . . . . . . . 51

Graco Standard Warranty ......................................... 52

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Summary of Contents for Compact Dyna-Star

Page 1: ...n explosive atmospheres or hazardous classified locations 3500 psi 24 1MPa 241 bar Maximum Working Pressure See page 3 for model information Related Manuals 3A6932 Compact Dyna Star Auto Fill Shut Off...

Page 2: ...Refill the Tank Pumps with an Auto fill Shut Off AFSO 16 Fill Pumps Without an Auto fill Shut Off AFSO 18 Refill the Tank Pumps without an Auto fill Shut Off 18 Operation 20 Priming the System 20 Pump...

Page 3: ...Description Metering System Feedback Tank Tank Accessories 1 12L 35 Bucket Length 24 VDC 0 Series Progressive no vent valve no pressure reporting 0 No Tank Bare Pump 0 No Tank Bare Pump 2 20L Tank Le...

Page 4: ...ep 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 g...

Page 5: ...nd 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 m...

Page 6: ...e pressure in the system use two wrenches working in opposite directions on the pump outlet fitting to slowly loosen the fitting only until no more lubricant or air is leaking from the fitting FIG 2 T...

Page 7: ...cation controller F The pump provides lubrication flow and pressure to operate metering devices AD Inlet and Outlet Components Vent Valve The vent valve L reduces system pressure in Series Parallel sy...

Page 8: ...N When needed the valve relieves pressure back into the pump tank K Motor Details The pump B is driven by a 24 V DC brushless motor 1 with a built in controller The motor LED flashes multiple times d...

Page 9: ...allel System Key A Lubricant output connection B Pump C Ignition switch D High pressure lubricant supply lines E Injector banks F Lubrication controller G Fill port H Overflow port K Tank L Vent Valve...

Page 10: ...gressive System Key A Lubricant output connection B Pump C Ignition switch D High pressure lubricant supply lines F Lubrication controller G Fill port H Overflow port K Tank NN Bearing AD Metering dev...

Page 11: ...Installation 3A6941B 11 Typical Wiring Series Parallel Systems FIG 6...

Page 12: ...lief valve P Outlet 3 8 in NPT R Gear box S Low level switch or level transducer T Pressure switch or transducer U Lift ring V Auto fill shut off AFSO optional Y Follower plate Z Tube in tube AB Plug...

Page 13: ...e tank through the fill port FIG 8 Auto Fill Shut Off When grease is added the follower plate is pushed upward and closes the flow path FIG 9 Non Auto Fill Shut Off When grease is added the follower p...

Page 14: ...lower plate to prime the pump for grease NLGI 1 NLGI 2 and for cold pumping applications Note The auto fill shut off requires using a follower plate The follower plate should not be used with oil and...

Page 15: ...FF Fill valve pressure relief knob Part of Fill Valve 77X542 GG Refilling line HH Instruction label Included with Fill Valve 77X542 JJ Supply hose K Tank V Auto Fill Shut Off V1 Auto Fill Shut Off va...

Page 16: ...remote fill station pump AA to a pressurized stall condition Note The operator must monitor the system during fill ing of the tank to prevent any accidental fluid overflow Refill the Tank Pumps with a...

Page 17: ...ill valve pressure relief knob FF long enough to relieve line pressure between fill valve EE and Auto fill Shut Off Valve V and between remote fill station pump AA and fill valve EE Note The length of...

Page 18: ...quipped with a follower plate Injury or amputation could result COMPONENT RUPTURE HAZARD The maximum working pressure of each component in the system may not be the same To reduce the risk of over pre...

Page 19: ...pump tanks K with a follower plate Y fill the tank until the follower plate reaches the overflow port H and grease flows out FIG 17 The breather J vents the tank to the atmosphere If it is plugged th...

Page 20: ...he vent valve L and starts the pump B 2 The pump B builds pressure in the supply lines D until all the injectors E actuate Then the pressure switch T sends a signal to the lubrication controller F to...

Page 21: ...m the bottom of the tank The fault activates when the remaining grease level is approximately 10 percent FIG 19 Low Level Switch NOTICE The pump B should not be run without grease because air will be...

Page 22: ...rom the bottom of the tank The fault activates when the remaining grease level is approximately 10 percent Light Indicator NOTICE The pump B should not be run without grease or air will be introduced...

Page 23: ...tch T closes Pressure Transducer The pressure transducer T is used for continuous pressure monitoring FIG 22 Output type 1 Switching output NO Operating voltage 24VDC Current 5A Connection type Packar...

Page 24: ...then remove the motor 1 and the o ring 2 FIG 24 4 Loosen and remove the four bolts and four washers holding the pump to the tank 41 with a 5 mm Allen wrench FIG 25 5 Pull the pump out of the tank 41...

Page 25: ...n to separate from the gear head 4 FIG 29 11 Remove the tube in tube 10 with a pipe wrench Verify the o ring 11 is on the tube in tube 10 FIG 30 12 Push on the end of the pump rod 27 to gain access to...

Page 26: ...y a cloth and tighten to steady the pump lower tube 23 FIG 33 16 Loosen the shovel tube 13 using a pipe wrench and remove it from the pump lower tube 23 FIG 33 17 Remove the two back up rings 14 and t...

Page 27: ...ings 20 and the o ring 21 from the piston bushing 19 FIG 36 23 Remove the shovel rod 17 from the pump piston 25 FIG 37 24 Remove the pump piston 25 from the pump rod 27 Note Remove the ball 22 from th...

Page 28: ...od FIG 41 27 Remove the retaining nut 9 located on the upper housing FIG 42 28 Remove the outer o ring 28 from the retaining nut FIG 43 29 Remove the throat screw 29 to get to the inner o ring 30 FIG...

Page 29: ...Maintenance 3A6941B 29 32 Remove the check valve and o ring 37 FIG 44 FIG 44 37...

Page 30: ...ining nut 9 with a new o ring and grease lightly FIG 46 4 Replace the outer o ring 28 from the retaining nut 9 with a new o ring and grease lightly FIG 46 5 Place the throat screw 29 into the retainin...

Page 31: ...ings 14 and o ring 15 with new back up rings and o ring and grease lightly FIG 50 9 Place the extension tube 26 over the pump rod and tighten to pump housing torque 40 ft lb 54 2 N m FIG 50 10 Place t...

Page 32: ...m FIG 52 and FIG 53 13 Replace the two back up rings 20 and o ring 21 with new back up rings and o ring and grease lightly FIG 54 14 Place the piston busing 19 into the pump lower tube 23 until seated...

Page 33: ...ovel tube 13 back up rings 14 and the o ring 15 and grease lightly FIG 58 21 Place the shovel tube 13 into the pump lower tube 23 and tighten torque 40 ft lb 54 2 N m FIG 58 22 Push pump rod 27 down t...

Page 34: ...it the pump assembly into the gear head 4 The retaining nut 9 can be loosened to increase the gap Line up the pump rod 27 with the cut out and slide into place FIG 62 Note Leave the retaining nut loos...

Page 35: ...FIG 64 30 Remove the two bolts 6 and two nuts 7 FIG 65 31 Place the protection cover 8 in place and secure with bolts 6 and nuts 7 not shown FIG 66 32 Place the o ring 2 and attach the motor 1 to the...

Page 36: ...re is air located between the pump tube and the tube in tube Remove this air by filling it with grease to prime the pump If this is not done the pump may lose priming during operation 34 Connect the r...

Page 37: ...nto the tank 41 through the cover and the gasket FIG 71 37 Place the four bolts and four washers into place and tighten with a 5 mm Allen wrench torque 16 ft lb 21 7 N m FIG 71 38 Place the pressure r...

Page 38: ...on Pump is not powering ON The red LED on the motor is not ON Wiring is incorrect Polarity is wrong Loose wire s Check and verify that the wire connections are tight Check and correct polarity Fuse is...

Page 39: ...ct polarity Replace the motor 4 blinks indicate low voltage Check voltage and correct as needed 5 blinks indicate high voltage Check voltage and correct as needed 6 blinks indicate an over temperature...

Page 40: ...ssary Follower plate is sunk into the tank The grease viscosity is too low Remove the follower plate The pump element parts are worn or damaged Replace with new pump element parts Pump is cycling ther...

Page 41: ...Parts 3A6941B 41 Parts 44 38 37 35 33 33 32 31 29 28 30 9 5 40 1 3 2 10 4 7 6 8 11 22 27 25 12 13 14 17 16 19 18 20 21 23 24 47 48 15 26...

Page 42: ...Parts 42 3A6941B 43 42 41 52 55 56 57 54 47 48 49 50 51 53...

Page 43: ...wer plate 20 Liter low level switch for AFSO models 1 25E167 Tank assembly with follower plate 20 Liter level transducer for AFSO models 1 58 25R124 Tank assembly 12 Liter low level switch no follower...

Page 44: ...s 5 56 M8 nut 5 57 M8 washer 5 Ref Part Description Qty Ref Part No Description 25P688 Motor Parts Kit 25P691 Tube in Tube 12 Liter Kit 25P692 Tube in Tube 20 Liter Kit 25P684 Protection Cover Kit 25P...

Page 45: ...ensions Pump with Tank 3A6941B 45 Dimensions Pump with Tank Ref 12 Liter 20 Liter inches mm inches mm A 24 53 623 1 30 48 774 2 B 14 43 366 5 20 38 517 7 C 11 48 291 6 11 48 291 6 D 13 9 353 1 13 9 35...

Page 46: ...one Pump 46 3A6941B Dimensions Stand Alone Pump Ref 12 Liter 20 Liter inches mm inches mm A 13 92 353 57 19 89 505 21 B 10 1 256 54 10 1 256 54 C 9 8 248 92 9 8 248 92 D 1 5 38 1 1 5 38 1 M 0 8 20 32...

Page 47: ...Dimensions Stand Alone Pump 3A6941B 47 Top View Dimensions Stand Alone Pump Ref 12 Liter 20 Liter inches mm E 7 63 193 8 F 2 54 64 52 G 3 26 82 83 H 6 79 172 47 K 10 18 258 6 Top View Bottom View...

Page 48: ...Mounting Dimensions Stand Alone Pump 48 3A6941B Mounting Dimensions Stand Alone Pump...

Page 49: ...Notes 3A6941B 49 Notes...

Page 50: ...um Delivery 4 5 in3 min 74 cc min Grease Tank Capacity Graco Supplied 12 or 20 Liters Inlet Outlet Size Tank Fill Port Quick Coupler Overflow Port 1 2 in npt Fluid Outlet 3 8 in npt Materials of Const...

Page 51: ...6941B 51 California Proposition 65 WARNING This product can expose you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm For more information g...

Page 52: ...n material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRA...

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