Graco Dyna-Star 3A6941J Instructions Manual Download Page 8

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Installation

3A6941J

Vent Valve

The vent valve (L) reduces system pressure in Series

Single Line system and resets the injectors.

Pressure Relief Valve

The pump design includes a self-contained pressure

relief valve (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 during start up and stays on during

operation. Refer to

Troubleshooting

, page 40 for more

information.

Motor Electrical Connection

. 3

. 4

Summary of Contents for Dyna-Star 3A6941J

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: ...th 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 Operat...

Page 3: ...1 12L 35 lb Bucket Length 24 VDC 0 Single Line Progressive no vent valve no pressure reporting 0 No Tank Bare Pump 0 No Tank Bare Pump 2 20L Tank Length 24 VDC 1 Vent Valve No Pressure Reporting 1 12L...

Page 4: ...eep 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...

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: ...supply and a timed signal from a lubrication controller F The pump provides lubrication flow and pressure to operate metering devices AD Inlet and Outlet Components NOTICE Fuses user supplied are req...

Page 8: ...self contained pressure relief valve 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 Th...

Page 9: ...arallel 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 Val...

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 3A6941J 11 Typical Wiring Single Line Parallel Systems FIG 7...

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: ...tank through the fill port FIG 9 Auto Fill Shut Off When grease is added the follower plate is pushed upward and closes the flow path FIG 10 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: ...n pump BB Remote fill station tank CC Filter DD Pressure relief line EE Fill valve Graco Part No 77X542 FF Fill valve pressure relief knob Part of Fill Valve 77X542 GG Refilling line HH Instruction la...

Page 16: ...n 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 an Auto fill Shut O...

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: ...DC G H Y Do not insert your finger into the overflow port while filling a tank equipped with a follower plate Injury or amputation could result COMPONENT RUPTURE HAZARD The maximum working pressure of...

Page 19: ...h a follower plate Y fill the tank until the follower plate reaches the overflow port H and grease flows out FIG 18 The breather J vents the tank to the atmosphere If it is plugged the tank will over...

Page 20: ...ses the 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 control ler...

Page 21: ...tance from the bottom of the tank The fault activates when the remaining grease level is approximately 10 percent FIG 20 NOTICE The pump B should not be run without grease because air will be introduc...

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 23 Output type 1 Switching output NO Operating voltage 24VDC Current 5A Connection type Packar...

Page 24: ...otor 1 and the o ring 2 FIG 25 4 Loosen and remove the four bolts 47 and four washers 48 holding the pump to the tank 41 with a 5 mm Allen wrench FIG 26 5 Loosen and remove the bolts 55 nuts 56 washer...

Page 25: ...rings attached Note The follower plate may sink into thinner fluids 9 Remove the pressure relief valve cartridge 5 FIG 31 10 Remove the two bolts 6 and two nuts not shown from the protective cover 8 F...

Page 26: ...head 4 FIG 34 14 Remove the tube in tube 10 with a pipe wrench Verify the o ring 11 is on the tube in tube 10 FIG 35 15 Push on the end of the pump rod 27 to gain access to the cross hole located at t...

Page 27: ...a cloth and tighten to steady the pump lower tube 23 FIG 38 19 Loosen the shovel tube 13 using a pipe wrench and remove it from the pump lower tube 23 FIG 38 20 Remove the two back up rings 14 and th...

Page 28: ...ings 20 and the o ring 21 from the piston bushing 19 FIG 41 26 Remove the shovel rod 17 from the pump piston 25 FIG 42 27 Remove the pump piston 25 from the pump rod 27 Note Remove the ball 22 from th...

Page 29: ...od FIG 46 30 Remove the retaining nut 9 located on the upper housing FIG 47 31 Remove the outer o ring 28 from the retaining nut FIG 48 32 Remove the throat screw 29 to get to the inner o ring 30 FIG...

Page 30: ...Maintenance 30 3A6941J 35 Remove the check valve and o ring 37 FIG 49 FIG 49 37...

Page 31: ...ining nut 9 with a new o ring and grease lightly FIG 51 4 Replace the outer o ring 28 from the retaining nut 9 with a new o ring and grease lightly FIG 51 5 Place the throat screw 29 into the retainin...

Page 32: ...ith new back up rings and o ring and grease lightly FIG 55 9 Place the extension tube 26 over the pump rod and tighten to pump housing torque 32 ft lb 43 4 N m FIG 55 Apply medium strength thread lock...

Page 33: ...m FIG 57 and FIG 58 13 Replace the two back up rings 20 and o ring 21 with new back up rings and o ring and grease lightly FIG 59 14 Place the piston bushing 19 into the pump lower tube 23 until seate...

Page 34: ...ovel tube 13 back up rings 14 and the o ring 15 and grease lightly FIG 63 21 Place the shovel tube 13 into the pump lower tube 23 and tighten torque 32 ft lb 43 4 N m FIG 63 22 Push pump rod 27 down t...

Page 35: ...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 67 Note Leave the retaining nut loos...

Page 36: ...FIG 69 30 Remove the two bolts 6 and two nuts 7 FIG 70 31 Place the protective cover 8 in place and secure with bolts 6 and nuts 7 not shown FIG 71 32 Place the o ring 2 and attach the motor 1 to the...

Page 37: ...pressure relief valve cartridge 5 and tighten torque 8 ft lb 10 8 N m FIG 74 Note There is air located between the pump tube and the tube in tube Remove this air by filling it with grease to prime th...

Page 38: ...76 37 Place the follower plate 42 into the tank NOTE The follower plate for the 60 lb tank has lift rings attached Note Best practice for thinner fluid is draining the fluid before placing the followe...

Page 39: ...lb tank is welded onto the cover and is not removable 40 Put the pump back into the tank 41 through the cover and the gasket 49 FIG 81 41 Place the four bolts 47 and four washers 48 into place and ti...

Page 40: ...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 41: ...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 42: ...of the tank Inspect and replace follower plate if necessary 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 Re...

Page 43: ...Parts 3A6941J 43 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 58...

Page 44: ...Parts 44 3A6941J 43 42 41 58 59 52 55 56 57 54 47 48 49 50 51 53...

Page 45: ...Liter level transducer for AFSO models 1 25E324 Tank assembly with follower plate 20 Liter low level switch for AFSO models 1 25E167 Tank assembly with follower plate 20 Liter level transducer for AFS...

Page 46: ...sducer Kit 60 lb 44 25P683 Front cover black with screws and label 1 45 130766 Warning label English not shown 1 46 130899 Warning Label French and Spanish not shown 1 47 M6 x 20 bolts 4 48 M6 Lock wa...

Page 47: ...ed with the Pump Part Number Motor X X X X X Vent Valve X X X Pressure Switch Pressure Reporting X Level Switch Level Reporting X X X Cable Harness Part Number 25P947 25R560 24N402 126331 one 1 each 2...

Page 48: ...1J Dimensions Pump with Tank Ref 12 Liter 20 Liter 60 lb inches mm inches mm inches mm A 24 53 623 1 30 48 774 2 28 4 721 4 B 14 43 366 5 20 38 517 7 18 2 462 3 C 11 48 291 6 11 48 291 6 15 08 383 0 D...

Page 49: ...Stand Alone Pump Ref 12 Liter 20 Liter 60 lb inches mm inches mm inches mm A 13 92 353 57 19 89 505 21 17 78 451 6 B 10 1 256 54 10 1 256 54 10 1 256 54 C 9 8 248 92 9 8 248 92 9 8 248 92 D 1 5 38 1...

Page 50: ...Dimensions Stand Alone Pump 50 3A6941J Dimensions Stand Alone Pump Ref 12 Liter 20 Liter 60 lb 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 51: ...Mounting Dimensions Stand Alone Pump 3A6941J 51 Mounting Dimensions Stand Alone Pump...

Page 52: ...Noise dBa Maximum sound pressure 70 dBa Low Level Switch Low Level Transducer Operating Voltage 0 30 VDC Output Type 1 Switching output NO 1 Analog output 1 5V pressure transducer Connection Type M12X...

Page 53: ...Technical Specifications 3A6941J 53 California Proposition 65 CALIFORNIA RESIDENTS WARNING Cancer and reproductive harm www P65warnings ca gov...

Page 54: ...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 WARRAN...

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