Graco Compact Dyna-Star 132662 Installation Instructions Manual
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Graco Compact Dyna-Star 132662 Installation Instructions Manual

Graco Compact Dyna-Star 132662 Installation Instructions Manual

Graco automatic lubrication system on the komatsu hd785
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Komatsu HD785 Installation
Instructions
Instructions for installing a Graco Compact Dyna-Star automatic
lubrication system on the Komatsu HD785.
Part No. 132662
Maximum System Working Pressure: 3500 psi (24.13 MPa, 241.3 bar)
Important Safety Information
Before beginning any installation, read all warnings and instructions in all related Graco component
manuals (page 1) and all related Original Equipment Manufacturer (OEM) manuals, including the vehi-
cle's Operation and Maintenance Manual (OMM). Save all instructions.
FLUID INJECTION HAZARD
Fluid leaks from incorrectly installed or ruptured compo-
nents, and/or failure to verify the components are properly
installed and tested, can result in serious injury such as
fluid spraying in the eyes or on skin and fluid injection, or
equipment damage.
Related Graco Component Manuals*
Manual No.
3A6941
3A7031
335023
*Refer to these instruction manuals for additional information related to the
installation and operation of system components.
The installation instructions contained in this manual are only a recommendation for an automatic lubrication system. They are
not intended to replace any instructions provided in the OEM's manuals. Always refer to the OEM's manuals for details on lubri-
cation intervals.
Manual Title
®
Compact Dyna-Star
Electric Pump
GLC X Lubrication Controller
™
™
GL-1 X
, GL-1 XL
Injectors
For professional use only.
NOTICE
Welding can damage electronics and the equipment's
structure. To help prevent equipment damage caused
by welding:
•
Disconnect the vehicle battery before welding.
•
Follow all welding guidelines in the OEM manuals,
including the OEM service manuals.
•
Only weld in locations specifically approved by the
OEM. Consult OEM dealership for information and
recommendations.
•
Perform all welding in accordance with American
Welding Standard (AWS) standards.

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Summary of Contents for Graco Compact Dyna-Star 132662

  • Page 1 Maximum System Working Pressure: 3500 psi (24.13 MPa, 241.3 bar) Important Safety Information Before beginning any installation, read all warnings and instructions in all related Graco component manuals (page 1) and all related Original Equipment Manufacturer (OEM) manuals, including the vehi- cle’s Operation and Maintenance Manual (OMM).

  • Page 2: Table Of Contents

    (F) RIGHT Direction Arrow / MANUAL Graco Information ......52 RUN / ENTER ........28 (G) LEFT Direction Arrow / Reset ....

  • Page 3: Installation Checklist

    Installation Checklist Installation Checklist The following checklist is provided as a tool to ensure all installation procedures are completed. Completed Description Page Disconnect the battery before beginning installation Walk around the truck; use a grease gun to verify that all lube points receive grease. Grease all zerks, before removal Remove zerks and Komatsu extensions.

  • Page 4: Recommended Tools And Supplies

    Recommended Tools and Supplies Recommended Tools and Supplies Size/Description Tool Metric Combination wrench* 1/4 in. - 15/16 in. 6 mm - 25 mm Socket set, standard and deep well with ratchet* 3/8 in. - 15/16 in. 9.5 mm - 25 mm Screwdrivers: standard and Phillips 1 short;...

  • Page 5: Typical Installation

    Typical Installation Typical Installation NOTE: Photographs may include optional equipment. 3A7633A...

  • Page 6: Installation

    Installation Installation Before You Start Zerk Fittings 1. Lubricate all zerk fittings and verify that every grease point is accepting grease (F . 2). See Grease Point Fitting Locations and Grease Point Fitting Table, page 7. Disconnect battery before installing the 2.

  • Page 7: Grease Point Fitting Locations

    Installation Grease Point Fitting Locations Location Reference Steering linkage (3 places each, right Steering cylinder and left) pin (4 places) Dump body hinge pin (1 place, right Steering link pin (5 and left) places) Rear suspension cylinder (2 places each, right and A-Arm (2 places left) each, right and...

  • Page 8: Injector Assembly And Installation

    Installation Injector Assembly and Left Side Injectors Installation 1. Assemble the 11-bank-injector assembly (F . 4 and . 5). Leave the plug in the manifold loose to Install the -4JIC x 90° elbows in the lower ports of all of purge the manifold and the main feed line.

  • Page 9: Right Side Injectors

    Installation Right Side Injectors 1. Assemble the 6-bank-injector assembly (F . 4 and . 7). Leave the plug in the manifold loose to purge the manifold and the main feed line. . 9: Right Side Injectors 4. Install the 6-bank-injector assembly using the included M12 x 30 bolts.

  • Page 10: Rear Injectors

    Installation Rear Injectors 1. Assemble two (2) 9-bank-injector assemblies (F and F . 10). Leave the plug (E) in the manifold loose to purge the manifold and the main feed line. 2. Install the two (2) 9-bank-injector assemblies onto the cross bar using the included M12 x 30 bolts .

  • Page 11: Injector Volume Output Adjustment Table

    Installation Injector Volume Output Adjustment Table Location Injector Turns Left Hand Manifold Upper Suspension Cyl Left Hand Manifold Rear A-Arm Left Hand Manifold Front A-Arm Left Hand Manifold Lower Suspension Cyl Left Hand Manifold Steering Tie Outer Left Hand Manifold Steering Cyl Outer Left Hand Manifold LH Steering Cyl Inner...

  • Page 12: P-Clamp Weld Studs

    Installation P-Clamp Weld Studs 3. Mark the location for the second of the weld studs, on top of the A-Arm near the rear pivot, centered on this portion of the arm 4 in. from the tread plate (F Lower A-Arms 16).

  • Page 13: Dump Body Cylinder Pins

    Installation Dump Body Cylinder Pins 1. Install six (6) p-clamp weld studs to the dump body: three on the inside of each side under the dump body above the frame rail (F . 18 - F . 20). 2. Center one (1) weld stud under each of the dump body support points, 2 in.

  • Page 14: Remote Fill Manifold

    Installation Remote Fill Manifold Remote Fill Manifold Installation 1. Attach the remote fill mounting bracket in front of the right front tire, on the rectangular boss with two (2) Assembling the Manifold M12 bolts (F . 23). 1. Install 3/4 in. x 3/8 in. NPT reducer bushing and 3/8 in.

  • Page 15: Compact Dyna-Star (Cds) Pump Assembly

    Installation Compact Dyna-Star (CDS) Pump Pump Installation Assembly 1. Remove the fill port and cover, optional outlet 1/4 in. npt plug, and 3/8 in. npt refill vent plug. LIFTING HAZARD 2. Install a 3/8 in. npt, 90° street elbow (A) and a 3/8 in. This equipment is heavy.
  • Page 16 Installation 3. Locate the reservoir mounting flange with the two 4. Place the reservoir mounting flange so that the fur- (2) mounting holes closest to the handrail, 10.0 in. thest hole from step 3 measures 29.5 in. (149.3 (354 mm) from the right hand side toe-kick plate mm) from the rear deck toe-kick plate (F .
  • Page 17 Installation 5. Mark the remaining holes using the bottom flange of the pump as the pattern. Drill the holes with a 5/16 drill bit. 6. Mount the pump using the supplied hardware (F 31 and F . 32). . 31 .

  • Page 18: Pump Harness Extension

    Installation Pump Harness Extension 5. Route the extension cable toward the front of the vehicle (F . 35). NOTE: Reference Wiring Diagram on page 27 for this section. 1. Remove the hand rail mounting bolts. Install the lad- der brackets under the bolt heads for tying off the cable and hoses.
  • Page 19 Installation 7. The 12 wires connect below the decking around the right front tire. The wires connect to an included 12-pin DT connector (F . 37). . 37 8. Crimp the pin contacts using proper DT crimping tool for solid size 16 contacts, according to proper DT connector crimping procedures and quality stan- dards.

  • Page 20: Glc X Controller

    GLC X Controller GLC X Controller Bracket Assembly 1. Unpack the GLC X bracket PN: 17G007 and lay the components on a clean flat surface. 2. Measure down 2 in. on both ends of the bracket (A). Bend each end to a 45° angle (G) (F .
  • Page 21 GLC X Controller 4. Install the GLC X mounting plate (F) to the mounting base plate (E) using bolts (B), washers (C) and nuts (D) as shown in F . 41. Be sure that plastic washer (H) is installed between the mounting plate (F) and mounting base plate (E) on the top and bottom.
  • Page 22 GLC X Controller 7. After removing the two bolt covers and bolts, adjust bracket fasteners (G) to align with the bolt holes in Step 6 (F . 44). 8. Tighten nuts (D) to secure bracket fasteners (G) to bracket (A) (F .

  • Page 23: Glc X Cable Routing

    GLC X Controller GLC X Cable Routing NOTE: Reference Wiring Diagram on page 27 for this section. 1. Remove the right side passenger seat by loosening the four (4) retaining bolts in the floor, under the seat. This allows access to the electrical housing .
  • Page 24 GLC X Controller 11. Pull a couple feet of cable through the grommet in the floor. A small hole must be cut in the grommet to do this (F . 53). 12. Route the 12 conductor cable along the floor under the door and through the access hole on the floor .
  • Page 25 GLC X Controller 16. Route the cable over the engine and next to the 17. Using the wire looms inside the engine bay, route radiator housing (F . 55). the GLC X cable down the electrical looms and toward the front of the radiator housing (F .

  • Page 26: Glc X Power Cable Connection

    GLC X Controller Add-a-Fuse Ground Wire . 60 . 58 4. Insert the fuse from BT1 10 into the add-a-fuse location furthest from the flying lead. Install the add-a-fuse assembly into the BT1 10 fuse slot (F 61). . 59 GLC X Power Cable Connection .

  • Page 27: Wiring Diagram

    GLC X Controller Wiring Diagram NOTE: Photographs may include optional equipment. 3A7633A...

  • Page 28: Glc X Controller Component Identification

    GLC X Controller (A) System LED GLC X Controller Component Light Status Identification Red (solid) Normal and ON Orange (solid) Controller is in system SETUP and NOTICE lubrication program is paused Red (flashing) System is in alarm To prevent damage to soft key buttons, do not press the buttons with sharp objects such as pens, plastic (B) Low Level Status LED cards, screwdrivers, or fingernails.

  • Page 29: Setup

    Setup Setup Navigating Setup and Data Entry Mode Select Interval. UP and DOWN Arrows: Interval • Press both the UP and DOWN Arrows simultaneously for three (3) seconds to Configures how frequently the GLC X lubricates the enter SETUP. product. •...

  • Page 30: Sensor

    Setup Sensor Start Up Defines the low level input as a continuous monitoring Navigate to the menu item start up. sensor. • Pre-lube: configures the GLC X to start a lubrication • Sensor Type: 0-10 V. event once powered on. •...

  • Page 31: Hose Assemblies

    Hose Assemblies Hose Assemblies Installing the Main Feed Line A list of the hose assemblies needed and the assembly requirements for both 3/8 in. and 8.6 mm hoses are pro- Junction vided in the Hose Length Table, page 33. NOTE: In the Hose Length Table: 1.
  • Page 32 Hose Assemblies 4. Connect the socket to the end of the hose. Rotate the fitting counter-clockwise to thread the hose fit- ting onto the hose until the socket is snug against the hose (F . 67). NOTE: A wrench and pliers may be needed to assist with this assembly.

  • Page 33: Hose Length Table

    Hose Assemblies Hose Length Table Length Cut Length Cut Length Manifold Location Lube Point Injector Size (overall) (in.) (mm) Remote Fill Primary Remote Fill 229.75 227.25 5772.15 Remote Fill Vent to Reservoir 236.50 234.00 5943.60 Primary Feed Pump to Cross Fitting 202.50 200.00 5080.00...

  • Page 34: Main Fill Line And Remote Fill Lines

    Hose Assemblies Hose Routing Main Fill Line and Remote Fill Lines 3. Leave enough slack in the hoses to attach to the handrail after all pump hoses are installed. 1. Starting from the pump, connect the remote fill vent hose to the back of the pump and the remote fill pri- 4.
  • Page 35 Hose Assemblies . 74 . 77 . 78 . 75 6. Securely tighten the fitting and ensure the hoses are secure using zip ties. 7. Remove the metal panels from the front right wheel well then route AFSO fill and vent hoses behind the paneling.
  • Page 36 Hose Assemblies . 79 . 82 . 80 . 83 . 81 NOTE: Photographs may include optional equipment. 3A7633A...

  • Page 37: Right Side Injector Manifold And Main Feed Line

    Hose Assemblies Right Side Injector Manifold and Main Feed Line 1. Attach the hose for the right side injector assembly to the -6JIC fitting of the cross assembly that is fac- ing the front of the haul truck and parallel to the pump main feed line (F .

  • Page 38: Left Side Injector Manifold

    Hose Assemblies Left Side Injector Manifold Rear Injector Manifold 1. Attach the hose feeding the left side injector mani- 1. Attach the hose feeding the rear injector manifold to fold to the other elbow port -6JIC fitting that faces the center cross fitting that faces the rear of the haul the front of the haul truck (F .

  • Page 39: Secondary Feed Lines

    Hose Assemblies 3. Attach the hose to the 90° elbow on the right side of Secondary Feed Lines the injector manifold (F . 91 and F . 92). Left Side Injector Assembly (F . 93 - F NOTE: Use existing hydraulic hoses, plumbing and standoffs to attach hoses.
  • Page 40 Hose Assemblies . 95 . 98 . 96 . 97 NOTE: Photographs may include optional equipment. 3A7633A...

  • Page 41: Right Side Injector Assembly

    Hose Assemblies Right Side Injector Assembly (F . 99 - F 102) NOTE: Use existing hydraulic hoses, plumbing and standoffs to attach hoses. Secure using the provided zip ties. . 101 . 99 . 100 . 102 NOTE: Photographs may include optional equipment. 3A7633A...

  • Page 42: Rear Injector Assembly

    Hose Assemblies Rear Injector Assembly (F . 103 - F . 113). . 106 . 103 . 107 . 104 . 108 . 105 NOTE: Photographs may include optional equipment. 3A7633A...
  • Page 43 Hose Assemblies . 109 . 112 . 110 . 113 5. Route the upper hoses off to each side and through p-clamps. Tie off to existing hoses or equipment . 110). . 111 NOTE: Photographs may include optional equipment. 3A7633A...

  • Page 44: P-Clamp Installation

    Hose Assemblies P-Clamp Installation 1. There are several p-clamps included in the kit for retaining hoses and securing to the frame. 2. The large p-clamp is to secure the cross fitting inside the frame of the haul truck (F . 64). 3.

  • Page 45: Fill The Injector Secondary Feed Hoses

    Hose Assemblies Fill the Injector Secondary Feed Fill Main Lines and CDS Hoses 1. Remove the remaining plugs from the injector mani- 1. Remove the zerk cap from the alternate injector out- folds. let port (F . 118). 2. Fill the CDS with grease using the Auto-Fill Shut Off valve.

  • Page 46: Testing

    Testing Testing Before testing the system: • Inspect the pressure gauge and ensure the pump reaches 3500 psi before the pressure switch • Be sure the CDS pump reservoir is filled. engages (F . 120). • Verify that all supply lines are connected securely (double check all hose connections).

  • Page 47: Troubleshooting

    Troubleshooting Troubleshooting NOTE: If the problem is not attributed to the Graco Lubrication System, consult the Komatsu Operations and Mainte- nance manual or your Komatsu dealer. Problem Cause Solution 1. Refill reservoir by using the AFSO fill port on the left hand side of the haul truck.
  • Page 48 If a replacement hose is impact. needed, use these extra parts to make a replacement or contact your local Graco distributor to order a replacement part. See Hose Assembly Instructions, on page 31, to assemble a replace- ment hose.
  • Page 49 Troubleshooting Problem Cause Solution Enter programming mode on the GLC X alarm output is not correctly Pump is always running GLC X controller and verify that Out- programmed. put is programmed to Vent Valve. Verify that the correct DT connector Pump is unresponsive The motor cable is disconnected.

  • Page 50: Parts

    Parts Parts FITTING, connector, 1/4T x 1/8P x 555749 Part No. Description 7/16 PUMP, Compact Dyna-Star, 20L CD2324 FITTING, elbow, 1/4T x 1/8MP 556763 GUARD, hose, 9 mm ID, 10M 123147 PLUG, pipe, 3/8 - 18 100040 BRACKET, mount 6 pos injector 132241 FITTING, elbow, street 155699...
  • Page 51 Parts California Proposition 65 CALIFORNIA RESIDENTS WARNING: Cancer and reproductive harm – www.P65warnings.ca.gov. NOTE: Photographs may include optional equipment. 3A7633A...

  • Page 52: Graco Information

    Graco Information For additional information about these Graco products; including Warnings, Troubleshooting, and Technical Data, refer to the Graco instruction manuals included with the equipment or visit the Graco website at www.graco.com to download the latest versions of Graco instruction manuals.

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