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Instructions
Compact Dyna-Star
Electric 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.
3500 psi (24.1MPa, 241 bar) Maximum Working
Pressure
See page 3 for model information.
Important Safety
Instructions
Read all warnings and instructions
in this manual and in your injector
manual before using the
equipment. Save these
instructions.
Related Manuals
3A6932 Compact Dyna-Star Auto-Fill Shut Off Kit
3A6998 Compact Dyna-Star 35 lb (5 Gallon) Kit
3A7035 Compact Dyna-Star Pump Cable
333393 Fill Valve
®
3A6941B
EN
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Table of Contents
Related Manuals for Graco Compact Dyna-Star 3A6941B
Summary of Contents for Graco Compact Dyna-Star 3A6941B
- Page 1 Instructions ® Compact Dyna-Star Electric Pump 3A6941B 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. 3500 psi (24.1MPa, 241 bar) Maximum Working Pressure See page 3 for model information.
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Page 2: Table Of Contents
Motor Details ......8 Graco Information ......52 Typical Installation: Series Parallel System . -
Page 3: Pump Model Selection Matrix
12 L Steel Tank Auto-Fill Shut Off, Level with no Follower Transducer Plate 20 L Steel Tank with no Follower Plate Note: Some pump configurations are not available. Contact Graco customer service or your local Graco distributor for assistance. 3A6941B... -
Page 4: Warnings
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 symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable. - Page 5 Warnings WARNING EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. • Do not operate the unit when fatigued or under the influence of drugs or alcohol. • Do not exceed the maximum working pressure or temperature rating of the lowest rated system com- ponent.
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Page 6: Installation
Installation Installation Grounding Pressure Relief Procedure Follow the Pressure Relief Procedure whenever you see this symbol. The equipment must be grounded to reduce the risk of static sparking. Static sparking can cause fumes to ignite or explode. Grounding provides an escape wire for the electric current. -
Page 7: Fuses
A fuse of the correct voltage and amperage must page 6. be installed in line with the power entry to the sys- tem. Graco recommends using a 10A time delay Pump fuse. The pump provides lubricant flow and pressure to oper- Mounting ate an automatic lubrication system. -
Page 8: Pressure Relief Valve
Installation Pressure Relief Valve Motor Details The pump design includes a self-contained pressure The pump (B) is driven by a 24 V DC brushless motor relief valve (N). When needed, the valve relieves (1) with a built-in controller. The motor LED flashes pressure back into the pump tank (K). -
Page 9: Typical Installation: Series Parallel System
Installation Typical Installation: Series Parallel System Key: Lubricant output connection* Pump Ignition switch* High-pressure lubricant supply lines* Injector banks* Lubrication controller* Fill port Overflow port Tank Vent Valve NN Bearing* *User provided 3A6941B... -
Page 10: Typical Installation: Series Progressive System
Installation Typical Installation: Series Progressive System Key: Lubricant output connection* Pump Ignition switch* High-pressure lubricant supply lines* Lubrication controller* Fill port Overflow port Tank NN Bearing* AD Metering device* *User provided 3A6941B... -
Page 11: Typical Wiring: Series Parallel Systems
Installation Typical Wiring: Series Parallel Systems 3A6941B... -
Page 12: Component Identification
Installation Component Identification Key:(Figure 6) Pump Pressure switch or transducer Fill port and cover Lift ring Overflow port Auto-fill shut off (AFSO) (optional) Breather Follower plate Tank Tube-in-tube Vent valve AB Plug to check venting / pressure relief Motor AC Refill vent plug or refill pressure relief Pressure relief valve AD Outlet (1/4 in. -
Page 13: Setup
Setup Setup Fill the Tank Auto-Fill Shut Off: When grease is added, the follower plate is pushed upward and closes the flow path. (F The fill port is used for filling and refilling the tank for pumps with or without auto-fill. Non-Auto-Fill Shut Off: When grease is added, the follower plate is pushed upward. - Page 14 Setup Always fill the pump through the fill port to expel any air from the tube-in-tube (F . 10). Tube-in-Tube . 10 Always use the follower plate to prime the pump for grease NLGI 1, NLGI 2, and for cold pumping applications.
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Page 15: Fill Pumps With An Auto-Fill Shut Off (Afso)
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 label* [Included with Fill Valve 77X542]... -
Page 16: Refill The Tank: Pumps With An Auto-Fill Shut Off (Afso)
Setup The auto-fill shut off (V) is used to refill the grease tank 2. Verify the auto-fill shut off pin (V2) is down, indicat- (K) in an automatic lubrication system. When the grease ing it is reset (F . 13). level in the tank is full, the auto-fill shut off automatically ends the filling operation. - Page 17 Setup 4. Connect the supply hose (JJ) between the remote 7. Turn off the remote fill station pump (AA). fill station pump (AA) and fill coupler (FC) port 8. Pull and hold the fill valve pressure relief knob (FF) marked with an “I” (F .
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Page 18: Fill Pumps Without An Auto-Fill Shut Off (Afso)
Setup Fill Pumps Without an Auto-fill Shut Off (AFSO) . 16 Key: AA Remote fill station pump* BB Remote fill station tank* CC Filter* DC Dust cap Fill port COMPONENT RUPTURE HAZARD JJ Supply hose* The maximum working pressure of each component Overflow port in the system may not be the same. - Page 19 Setup 1. Connect the lubricant supply hose (JJ) from the remote filling station pump (AA) to the fill port (G) . 17). . 17 The breather (J) vents the tank to the atmosphere. If it is plugged the tank will over-pressurize and rupture. Be sure the breather is not plugged before filling the pump.
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Page 20: Operation
Operation Operation Note: Upper case letters used in the following 4. Reconnect the high pressure lubricant supply line instructions refer to Component Identification, Typical (D) to the outlet. Installation: Series Parallel System and Typical Installation: Series Progressive System diagrams Pump Operation Overview starting on page 9. -
Page 21: Level Monitoring
Operation Level Monitoring NOTICE The pump (B) should not be run without grease Low Level Switch because air will be introduced into the system and could cause damage. The low level switch (S) (F . 19) indicates a fault when the follower plate (Y) reaches the factory set distance from the bottom of the tank. -
Page 22: Level Transducer
Operation Level Transducer The level transducer (S) (F . 21) is used for continuous level monitoring. It indicates a fault when the follower plate (Y) reaches the factory set distance from the bottom of the tank. The fault activates when the remaining grease level is approximately 10 percent. -
Page 23: Pressure Switch
Operation Pressure Switch Pressure Transducer The pressure switch (T) is factory set to 3000 psi (20.7 The pressure transducer (T) is used for continuous MPa, 207 bar) (F . 22). pressure monitoring. Output type: Analog 1- 5V Operating voltage: 8 - 32V Connection type: Packard Metri-Pack 150 Series Pressure range:... -
Page 24: Maintenance
Maintenance Maintenance 5. Pull the pump out of the tank (41). 6. Remove the pressure relief valve cartridge (5) (F 26). Disassemble 1. Relieve pressure, following the Pressure Relief Procedure, page 6. 2. Disconnect the power to the system. 3. Loosen and remove the four bolts (3) holding the motor (1) to the pump, then remove the motor (1) and the o-ring (2) (F . - Page 25 Maintenance 9. Loosen the retaining nut (9) with a tube wrench (F 28). . 30 12. Push on the end of the pump rod (27) to gain . 28 access to the cross-hole located at the end of the shovel rod (F .
- Page 26 Maintenance 13. Place an Allen wrench or similar tool through the 18. Loosen and remove the pump lower tube (23) with a slot of the shovel tube (13) and into the exposed pipe wrench and remove the o-ring (24) from the cross-hole to keep the shovel rod (17) steady (F pump lower tube (23) (F .
- Page 27 Maintenance 21. Remove the piston bushing (19) (F . 36). 24. Remove the pump piston (25) from the pump rod (27). 22. Remove the two (2) backup rings (20) and the o-ring (21) from the piston bushing (19) (F . 36). Note: Remove the ball (22) from the pump piston (25) .
- Page 28 Maintenance 25. Loosen and remove the extension tube (26) from 27. Remove the retaining nut (9) located on the upper the top housing. Remove two backup rings (14) and housing (F . 42). the o-ring (15) (F . 40). . 42 28.
- Page 29 Maintenance 32. Remove the check valve and o-ring (37) (F . 44). . 44 3A6941B...
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Page 30: Reassemble
Maintenance Reassemble 5. Place the throat screw (29) into the retaining nut (9) using an Allen wrench and tighten (torque 16 ft-lb/ 21.7 N•m) 1. Place throat seal (32) (u-cup) into the pump housing, lips downward (F . 45). 2. Place the bronze washer (31) on top of the throat seal (32) (u-cup) (F . - Page 31 Maintenance 7. Apply a light coating of grease to the pump rod (27) and push it into the pump housing through the hole in the retaining nut (9) (F . 49). Pump Housing . 49 . 50 8. Replace the two back-up rings (14) and o-ring (15) with new back-up rings and o-ring and grease lightly 10.
- Page 32 Maintenance 12. Place the pump piston (25) on the end of the pump 13. Replace the two back-up rings (20) and o-ring (21) rod (27) and tighten using wrenches (torque 10 with new back-up rings and o-ring and grease lightly ft-lb/13.6 N•m) (F .
- Page 33 Maintenance 16. Replace and lightly grease the o-ring (24) on the 20. Replace the two shovel tube (13) back-up rings (14) lower pump tube (23) (F . 56). and the o-ring (15) and grease lightly (F . 58). 17. Slide the pump lower tube (23) over the pump rod 21.
- Page 34 Maintenance 25. Replace the o-ring (11) and grease lightly (F . 60). 27. Fit the pump assembly into the gear head (4). The retaining nut (9) can be loosened to increase the 26. Slide the tube-in-tube (10) over the assembly and gap.
- Page 35 Maintenance 29. Tighten the retaining nut (9) with a wrench (torque 31. Place the protection cover (8) in place and secure 30 ft-lb/40.1 N•m) to secure (F . 64). with bolts (6) and nuts (7) (not shown) (F . 66). .
- Page 36 Maintenance 33. Place the o-ring onto the check valve, and then prime the pump. If this is not done, the pump may lose place into the pump outlet and tighten (torque 16 priming during operation. ft-lb/21.7 N•m) (F . 68). 34.
- Page 37 Maintenance 35. Run the refill pump until grease comes out of the bottom of the tube-in-tube (F . 70). . 71 38. Place the pressure relief valve cartridge (5) and tighten (torque 8 ft-lb/10.8 N•m) (F . 72). . 70 36.
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Page 38: Troubleshooting
Troubleshooting Troubleshooting 1. Follow Pressure Relief Procedure, page 6, before checking or repairing the pump. 2. Check all possible problems and causes before disassembling the pump. Problem Cause Solution Wiring is incorrect Check and verify that the wire Polarity is wrong connections are tight. - Page 39 Troubleshooting Problem Cause Solution 2 blinks indicate: Remove the pump and repair with over current new pump element parts. pump is jammed 2 blinks indicate: Replace the grease if it is too thick over current or the ambient temperature is too pump is jammed cold to pump the grease.
- Page 40 Troubleshooting Problem Cause Solution Tank was not refilled through the fill Connect the refill pump to the fill port port. Air in the tube-in-tube was and fill tank to remove any air. pushed into the grease tank. Grease inside of the tank is not Install follower plate to help moving to the pump shovel tube.
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Page 41: Parts
Parts Parts 3A6941B... - Page 42 Parts 55, 56, 57 3A6941B...
- Page 43 Parts Part No./Description Ref. Part Description Qty. Ref. Part Description Qty. Tank assembly with follower plate Motor 25E323 12 Liter, level transducer for AFSO O-ring models Motor bolts Tank assembly with follower plate Gear head 25E324 20 Liter, low level switch for AFSO 25R009 Pressure relief valve models ...
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Page 44: Related Kits
Parts Related Kits Ref. Part Description Qty. Eye bolt Part No. Description Tank cover 25P688 Motor Parts Kit M8 x 32 bolts 25P691 Tube-in-Tube 12 Liter Kit M8 nut 25P692 Tube-in-Tube 20 Liter Kit ... -
Page 45: Dimensions: Pump With Tank
Dimensions: Pump with Tank Dimensions: Pump with Tank 12 Liter 20 Liter inches inches 24.53 30.48 623.1 774.2 14.43 20.38 366.5 517.7 11.48 11.48 291.6 291.6 13.9 13.9 353.1 353.1 3A6941B... -
Page 46: Dimensions: Stand Alone Pump
Dimensions: Stand Alone Pump Dimensions: Stand Alone Pump Top View 12 Liter 20 Liter inches inches 13.92 19.89 353.57 505.21 10.1 10.1 256.54 256.54 248.92 248.92 38.1 38.1 20.32 20.32 3A6941B... -
Page 47: Dimensions: Stand Alone Pump
Dimensions: Stand Alone Pump Dimensions: Stand Alone Pump Top View Top View Bottom View 12 Liter/20 Liter inches 7.63 193.8 2.54 64.52 3.26 82.83 6.79 172.47 10.18 258.6 3A6941B... -
Page 48: Mounting Dimensions: Stand Alone Pump
Mounting Dimensions: Stand Alone Pump Mounting Dimensions: Stand Alone Pump 3A6941B... -
Page 49: Notes
Notes: Notes: 3A6941B... -
Page 50: Technical Specifications
Peak Operating Current 15 A Peak Power 188 Watts Maximum Delivery* 74 cc/min 4.5 in /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... -
Page 51: California Proposition 65
Technical Specifications 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, go to www.P65warnings.ca.gov. 3A6941B... -
Page 52: Graco Standard Warranty
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.