Graco Dyna-Star 3A6941J Instructions Manual
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Graco Dyna-Star 3A6941J Instructions Manual

Graco Dyna-Star 3A6941J Instructions Manual

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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
®
3A6941J
EN

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Summary of Contents for Graco Dyna-Star 3A6941J

  • Page 1 Instructions ® Compact Dyna-Star Electric Pump 3A6941J 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.

  • Page 2: Table Of Contents

    Inlet and Outlet Components....7 Graco Information ......54 Vent Valve .

  • Page 3: Pump Model Selection Matrix

    20 L Steel Tank with no Follower Plate 60 lb. Steel Tank with Follower Plate 60 lb. Steel Tank with no Follower Plate Note: Some pump configurations are not available. Contact Graco customer service or your local Graco distributor for assistance. 3A6941J...

  • 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-spe- cific 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 component.

  • 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 5. Ground the system. See Grounding instructions, be installed in line with the power entry to the sys- page 6. tem. Graco recommends using a 10A time delay fuse. Pump Mounting The pump provides lubricant flow and pressure to oper- ate an automatic lubrication system.

  • Page 8: Vent Valve

    Installation Motor Electrical Connection 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).

  • Page 9: Typical Installation: Single Line Parallel System

    Installation Typical Installation: Single Line 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 3A6941J...

  • 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 3A6941J...

  • Page 11: Typical Wiring: Single Line Parallel Systems

    Installation Typical Wiring: Single Line Parallel Systems 3A6941J...

  • 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 The fill port is used for filling and refilling the tank for plate is pushed upward and closes the flow path. (F pumps with or without auto-fill. 10).
  • Page 14 Setup Always fill the pump through the fill port to expel any air from the tube-in-tube (F . 11). Tube-in-Tube . 11 Always use the follower plate to prime the pump for grease NLGI 1, NLGI 2, and for cold pumping applications.

  • Page 15: Fill Pumps With An Auto-Fill Shut Off (Afso)

    (dead-head) there is a leak in the system. Note: The fill pump pressure can be as high as 2000 psi, depending upon the lengths and diameters of Refilling line (GG) and Supply hose (JJ). Graco recommends using a 36:1 ratio, or higher, air operated fill pump. NOTICE...

  • 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 . 14). 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 .

  • Page 18: Fill Pumps Without An Auto-Fill Shut Off

    Fill Pumps Without an Auto-fill Shut Off (AFSO) Note: The fill pump pressure can be as high as 2000 psi, depending upon the length and diameter of Supply hose (JJ). Graco recommends using a 36:1 ratio, or higher, air operated fill pump. . 17...
  • Page 19 Setup 1. Connect the lubricant supply hose (JJ) from the remote filling station pump (AA) to the fill port (G) . 18). . 18 The breather (J) vents the tank to the atmosphere. If it is plugged the tank will over-pressurize and rupture, potentially causing serious injury.

  • 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, (D) to the outlet. Typical Installation: Single Line Parallel System and Typical Installation: Series Progressive System Pump Operation Overview diagrams 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 . 20) 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 . 22) 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 . 23). 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. Loosen and remove the bolts (55), nuts (56), washer (57), and lifting ring (53) from the cover. NOTE: The lift ring for the 60 lb. tank is welded onto the cover and is not removable. Disassemble 1. Relieve pressure, following the Pressure Relief Procedure, page 6.
  • Page 25 Maintenance 7. Remove the cover (54). 9. Remove the pressure relief valve cartridge (5) (F 31). . 29 . 31 8. Remove the follower plate (42) and set aside. 10. Remove the two bolts (6) and two nuts (not shown) from the protective cover (8) (F .
  • Page 26 Maintenance . 33 . 35 13. Pull up on the lower section to separate from the 15. Push on the end of the pump rod (27) to gain gear head (4) (F . 34). access to the cross-hole located at the end of the shovel rod (F .
  • Page 27 Maintenance 16. Place an Allen wrench or similar tool through the 21. Loosen and remove the pump lower tube (23) with slot of the shovel tube (13) and into the exposed a 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 28 Maintenance 24. Remove the piston bushing (19) (F . 41). 27. Remove the pump piston (25) from the pump rod (27). 25. Remove the two (2) backup rings (20) and the o-ring (21) from the piston bushing (19) (F . 41). Note: Remove the ball (22) from the pump piston (25) .
  • Page 29 Maintenance 28. Loosen and remove the extension tube (26) from 30. Remove the retaining nut (9) located on the upper the top housing. Remove two backup rings (14) and housing (F . 47). the o-ring (15) (F . 45). . 47 31.
  • Page 30 Maintenance 35. Remove the check valve and o-ring (37) (F . 49). . 49 3A6941J...

  • Page 31: 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 . 50). 2. Place the bronze washer (31) on top of the throat seal (32) (u-cup) (F .
  • Page 32 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 . 54). Pump Housing . 54 . 55 8. Replace the two back-up rings (14) and o-ring (15) with new back-up rings and o-ring and grease 10.
  • Page 33 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 ft-lb/13.6 N•m) (F .
  • Page 34 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 . 61). and the o-ring (15) and grease lightly (F . 63). 17. Slide the pump lower tube (23) over the pump rod 21.
  • Page 35 Maintenance 25. Replace the o-ring (11) and grease lightly (F . 65). 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 36 Maintenance 29. Tighten the retaining nut (9) with a wrench (torque 31. Place the protective cover (8) in place and secure 30 ft-lb/40.1 N•m) to secure (F . 69). with bolts (6) and nuts (7) (not shown) (F . 71). .
  • Page 37 Maintenance 33. Place the o-ring onto the check valve, and then place into the pump outlet and tighten (torque 16 ft-lb/21.7 N•m) (F . 73). . 74 Note: There is air located between the pump tube and . 73 the tube-in-tube. Remove this air by filling it with grease 34.
  • Page 38 Maintenance 35. Connect the refill pump to the fill coupler (F . 75). 37. Place the follower plate (42) into the tank. NOTE: The follower plate for the 60 lb. tank has lift rings attached. Fill Coupler Refill Pump . 75 .
  • Page 39 Maintenance 39. Replace and tighten the bolts (55), nuts (56), 40. Put the pump back into the tank (41) through the washers (57), and lifting ring (53) back onto the cover and the gasket (49) (F . 81). cover (54). NOTE: The lift ring for the 60 lb.

  • Page 40: 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 41 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 42 Troubleshooting Problem Cause Solution Tank was not refilled through the fill Connect the refill pump to the fill port. Air in the tube-in-tube was port and fill tank to remove any air. pushed into the grease tank. Airlock inside of the pump. Remove the pump outlet check valve and o-ring (37).

  • Page 43: Parts

    Parts Parts 3A6941J...
  • Page 44 Parts 55, 56, 57 41, 58, 59 3A6941J...
  • Page 45 Parts Part No./Description Ref. Part Description Qty. Ref. Part Description Qty. 25E166 Tank assembly with follower plate Motor ❊ 12 Liter, low level switch for O-ring ❊ AFSO models Motor bolts ❊ 25E323 Tank assembly with follower plate Gear head 12 Liter, level transducer for 25R009 Pressure relief valve AFSO models...

  • Page 46: Related Kits

    Parts Ref. Part Description Qty. Ref. Part Description Qty. 26B643 Tank assembly with follower plate ‡ Overflow tube 60 lb., low level switch overflow Eye bolt (12L and 20L only) ✓ Top View tube. Tank cover ✓ 26B642 Tank assembly with follower plate Bolts ✓...
  • Page 47 Parts Cable Harness . 82 Cable Harness Part Number (Included with the Pump Part Number* Motor Vent Valve Pressure Switch/Pressure Reporting Level Switch/Level Reporting 24N402, 126331 24N402 - two (2) Cable Harness Part 25P947 25R560 24N402 - one (1) each pieces Number Refer Cable Manual...

  • Page 48: Dimensions: Pump With Tank

    Dimensions: Pump with Tank Dimensions: Pump with Tank 12 Liter 20 Liter 60 lb. inches inches inches 24.53 30.48 28.4 623.1 774.2 721.4 14.43 20.38 18.2 366.5 517.7 462.3 11.48 11.48 15.08 291.6 291.6 383.0 13.9 13.9 15.6 353.1 353.1 396.2 3A6941J...

  • Page 49: Dimensions: Stand Alone Pump

    Dimensions: Stand Alone Pump Dimensions: Stand Alone Pump 12 Liter 20 Liter 60 lb. inches inches inches 13.92 19.89 17.78 353.57 505.21 451.6 10.1 10.1 10.1 256.54 256.54 256.54 248.92 248.92 248.92 38.1 38.1 38.1 20.32 20.32 20.32 3A6941J...

  • Page 50: Dimensions: Stand Alone Pump

    Dimensions: Stand Alone Pump Dimensions: Stand Alone Pump Top View Bottom View 12 Liter/20 Liter/60 lb. inches 7.63 193.8 2.54 64.52 3.26 82.83 6.79 172.47 10.18 258.6 3A6941J...

  • Page 51: Mounting Dimensions: Stand Alone Pump

    Mounting Dimensions: Stand Alone Pump Mounting Dimensions: Stand Alone Pump 3A6941J...

  • Page 52: Technical Specifications

    Maximum Current 10 A Peak Operating Current 15 A 74 cc/min Maximum Delivery* 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 53: California Proposition 65

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

  • Page 54: 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.

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