Graco Compact Dyna-Star 132662 User manual

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.
Mobile Lubrication Library
Komatsu HD785 Installation
Instructions
Instructions for installing a Graco Compact Dyna-Star automatic
lubrication system on the Komatsu HD785. For professional use only.
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.
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.
Related Graco Component Manuals*
Manual No. Manual Title
3A6941 Compact Dyna-Star®Electric Pump
3A7031 GLC X Lubrication Controller
335023 GL-1 X™, GL-1 XL™Injectors
*Refer to these instruction manuals for additional information related to the
installation and operation of system components.
3A7633A

Table of Contents
23A7633A
NOTE: Photographs may include optional equipment.
Table of Contents
Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . 3
Recommended Tools and Supplies . . . . . . . . . . . . . . 4
Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . 4
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Before You Start . . . . . . . . . . . . . . . . . . . . . . . . . 6
Zerk Fittings ...................................................6
Grease Point Fitting Locations . . . . . . . . . . . . . . 7
Grease Point Fitting Table . . . . . . . . . . . . . . . . . 7
Injector Assembly and Installation . . . . . . . . . . . 8
Left Side Injectors ..........................................8
Right Side Injectors .......................................9
Rear Injectors .............................................. 10
Set the Injector Output ................................. 10
Injector Volume Output Adjustment Table ... 11
P-Clamp Weld Studs . . . . . . . . . . . . . . . . . . . . . 12
Lower A-Arms .............................................. 12
Dump Body Cylinder Pins ............................ 13
Remote Fill Manifold . . . . . . . . . . . . . . . . . . . . . 14
Assembling the Manifold ............................. 14
Remote Fill Manifold Installation .................. 14
Compact Dyna-Star (CDS) Pump Assembly . . . 15
Fitting Table ................................................. 15
Pump Installation . . . . . . . . . . . . . . . . . . . . . . . 15
Pump Harness Extension ............................ 18
GLC X Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . 20
GLC X Cable Routing . . . . . . . . . . . . . . . . . . . . 23
GLC X Power Cable Connection . . . . . . . . . . . 26
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 27
GLC X Controller Component Identification 28
(A) System LED ........................................... 28
(B) Low Level Status LED ........................... 28
(D and E) UP and DOWN Direction Arrows 28
(F) RIGHT Direction Arrow / MANUAL
RUN / ENTER ....................................... 28
(G) LEFT Direction Arrow / Reset ................ 28
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Navigating Setup and Data Entry . . . . . . . . . . . 29
Change Settings . . . . . . . . . . . . . . . . . . . . . . . . 29
Mode ........................................................... 29
End On ........................................................ 29
Low Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Sensor ......................................................... 30
Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Enable a Lock out PIN ................................ 30
Entering a PIN ............................................. 30
Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Output 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Date and Time ............................................ 30
Additional Advanced Features . . . . . . . . . . . . . . 30
Hose Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Installing the Main Feed Line Junction . . . . . . . 31
Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 31
Hose Assembly Instructions . . . . . . . . . . . . . . . 31
Hose Length Table . . . . . . . . . . . . . . . . . . . . . . 33
Main Fill Line and Remote Fill Lines ........... 34
Right Side Injector Manifold and Main
Feed Line .............................................. 37
Left Side Injector Manifold .......................... 38
Rear Injector Manifold ................................. 38
Secondary Feed Lines . . . . . . . . . . . . . . . . . . . . 39
Left Side Injector Assembly ........................ 39
Right Side Injector Assembly ....................... 41
Rear Injector Assembly. .............................. 42
P-Clamp Installation . . . . . . . . . . . . . . . . . . . . . 44
Fill the Injector Secondary Feed Hoses . . . . . . . 45
Fill Main Lines and CDS . . . . . . . . . . . . . . . . . . 45
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Installation Checklist
3A7633A 3
NOTE: Photographs may include optional equipment.
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 7
Walk around the truck; use a grease gun to verify that all lube points receive grease. 6
Grease all zerks, before removal 6
Remove zerks and Komatsu extensions. 6
Install grease point fittings 7
Assemble Injectors 8
Install remote fill manifold 14
Assemble the pump and fittings 15
Install and route pump power cable 18
Mount GLC X Controller bracket assembly 20
GLC X Controller cable routing 23
Wire the GLC X Controller 26
Wire the pump to the GLC X Controller 28
Program GLC X Controller 29
Install the main feed line 31
Cut hoses to length, apply hose wraps and fittings 33
Hose Routing between Injectors and Grease Points. DO NOT CONNECT 34
Install P-clamps 44
Reconnect the battery 7
Fill the pump reservoir with grease; purge the main feed line 45
Connect and tighten all lines and fittings 45
Run test program; verify all connections are tight; verify all points are receiving lubricant 46

Recommended Tools and Supplies
43A7633A
NOTE: Photographs may include optional equipment.
Recommended Tools and Supplies
*Both US and Metric sizes of these tools are recommended.
Loctite®is a registered trademark of the Henkel Corporation.
All other Trademarks used herein are the property of their respective owners.
Installation Notes
• Before installation prime and paint all bare metal
surfaces with matching Komatsu primer and paint.
• Refer to the Installation Checklist, provided on
page 3, to ensure that all installation procedures are
completed in the correct order.
• Do not use PTFE tape on fitting threads. Liquid
thread sealant is recommended for use in lubrica-
tion systems to eliminate the potential for contami-
nation. If you must use PTFE tape, always skip the
first two threads on the fitting.
Tool
Size/Description
US 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; 1 long
Adjustable wrench 1 small; 1 medium
Impact wrench
Drill (corded or cordless)
Drill bits 5/16 in., 11/16 in.
Center punch fine point
Pipe taper tap 1/8 in. NPT
Hammer
Angle grinder
Grinding disc Heavy grade grinding disc
Flap disc 60 - 80 grit
Cutoff disc High quality disc
Cutting blade / knife Razor blade cutting tool
Standard pliers
Needle nose pliers
Side cut pliers (diagonal cutters)
Slip joint pliers
Locking pliers Small or medium
Electrician’s wire stripper / crimper General duty wire stripper / crimper
Soldering iron 30 watt minimum
Electrical solder
Soldering flux
Shrink tubing Various sizes
Electrical tape Black, small roll
Thread sealant Liquid thread sealant such as Loctite®565
Multi-tester / voltmeter Must test DC/AC/Ohms
Electrical connectors Ring connectors (10, 18 and 24 gauge)
Tape measure Standard / metric
Komatsu primer and paint Color should match the Komatsu equipment
Documentation / writing implements Small note pad, pen, pencil, marker

Typical Installation
3A7633A 5
NOTE: Photographs may include optional equipment.
Typical Installation

Installation
63A7633A
NOTE: Photographs may include optional equipment.
Installation
Before You Start
.
Zerk Fittings
1. Lubricate all zerk fittings and verify that every
grease point is accepting grease (FIG. 2). See
Grease Point Fitting Locations and Grease Point
Fitting Table, page 7.
2. Use a clean cloth or rag to remove any remaining
grease, contaminants or dirt from the area around
the passage way to the grease points.
3. Remove zerk fittings and extensions (FIG. 3).
4. Install Grease Point Fittings per table on page 7.
Apply pipe sealant to fittings. To avoid contamina-
tion do not use PTFE tape on the fitting threads. If
you must use PTFE tape, always ensure that the
first thread on the fitting is not taped and the tape is
applied precisely.
Disconnect battery before installing the
lubrication equipment (FIG. 1). Installing
lubrication equipment on powered machin-
ery could result in serious injury from skin
injection or parts moving unexpectedly, and
could damage the vehicle.
FIG. 1 FIG. 2
FIG. 3

Installation
3A7633A 7
NOTE: Photographs may include optional equipment.
Grease Point Fitting Locations
]\
Grease Point Fitting Table
1
Location Reference
Steering cylinder
pin (4 places)
Steering link pin (5
places)
A-Arm (2 places
each, right and
left)
Hoist cylinder pin
(2 places each,
right and left)
Front suspension
cylinder (2 places
each, right and
left)
Steering linkage (3
places each, right
and left)
Dump body hinge
pin (1 place, right
and left)
Rear suspension
cylinder (2 places
each, right and
left)
Differential
support (4 places
each, right and
left)
Lubrication Point Part No. Description Qty
Front Suspension
Cylinder (Upper and
Lower)
17K061 1/8 BSPT x 1/8 in. NPT elbow 4
555749 1/8 in. NPT x -4 JIC Straight 4
A-Arm
17K062 1/8 BSPT Long extension 4
17K061 1/8 BSPT x 1/8 in. NPT elbow 4
555749 1/8 in. NPT x -4 JIC Straight 4
All Other Front
Lubrication Points
17K061 1/8 BSPT x 1/8 in. NPT elbow 15
555749 1/8 in. NPT x -4 JIC Straight 15
Dump Body
Cylinders
17K061 1/8 BSPT x 1/8 in. NPT elbow 4
555749 1/8 in. NPT x -4 JIC Straight 4
All Rear Axle
Lubrication Points
17K061 1/8 BSPT x 1/8 in. NPT elbow 14
555749 1/8 in. NPT x -4 JIC Straight 14

Installation
83A7633A
NOTE: Photographs may include optional equipment.
Injector Assembly and
Installation
Install the -4JIC x 90° elbows in the lower ports of all of
the injectors and the Zerk caps into the top ports of all of
the injectors (FIG. 4).
Left Side Injectors
1. Assemble the 11-bank-injector assembly (FIG. 4 and
FIG. 5). Leave the plug in the manifold loose to
purge the manifold and the main feed line.
2. Remove the three M12 bolts from the frame behind
the left front tire holding the rear portion of the
guarding in place.
3. Install the 11-bank-injector assembly using the
included M12 x 30 bolts (FIG. 6).
FIG. 4
Elbow
Zerk cap
FIG. 5: Left Side Injectors
FIG. 6
A
B
C
F
E

Installation
3A7633A 9
NOTE: Photographs may include optional equipment.
Right Side Injectors
1. Assemble the 6-bank-injector assembly (FIG. 4 and
FIG. 7). Leave the plug in the manifold loose to
purge the manifold and the main feed line.
2. Remove the two M12 bolts from the frame behind
the right front tire holding the rear guarding in place.
3. Cut the boss interfering with the injector assembly.
When completed, it should look like FIG. 8.
4. Install the 6-bank-injector assembly using the
included M12 x 30 bolts.
FIG. 7: Right Side Injectors
FIG. 8
A
BC
G
E
FIG. 9: Right Side Injectors

Installation
10 3A7633A
NOTE: Photographs may include optional equipment.
Rear Injectors
1. Assemble two (2) 9-bank-injector assemblies (FIG. 4
and FIG. 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
(FIG. 10).
3. Remove two (2) per side M14 bolts holding the rear
light mounting assembly (FIG. 11).
4. Bend the upper suspension cylinder lube line to
allow clearance for installing the mounting bracket
on both the left and right sides (FIG. 12).
5. Install the cross bar with the two (2) 9-bank-injector
assemblies.
Set the Injector Output
1. Turn the adjustment nut (A) clockwise (down) until
the head engages the cycle pin (B). (FIG. 13.)
2. Turn the adjustment nut (A) clockwise (down) to set
the output volume. Refer to the Injector Volume
Output Adjustment Table, page 11, to determine
the number of turns needed to obtain the desired
output value.
NOTE:Be sure the pin locating hole (C) faces out-
ward for operator inspection (FIG. 13).
3. Tighten the lock nut (D) to retain the adjustment
position (FIG. 13).
4. Install the o-ring (E) and cap (F) to protect the pin
from contamination (FIG. 13).
FIG. 10: Rear Injectors
FIG. 11
E
FIG. 12
FIG. 13
A
B
C
D
E
F

Installation
3A7633A 11
NOTE: Photographs may include optional equipment.
Injector Volume Output Adjustment Table
Location Injector Turns
1 Left Hand Manifold Upper Suspension Cyl 0
2 Left Hand Manifold Rear A-Arm 2
3 Left Hand Manifold Front A-Arm 2
4 Left Hand Manifold Lower Suspension Cyl 0
5 Left Hand Manifold Steering Tie Outer 2
6 Left Hand Manifold Steering Cyl Outer 2
7 Left Hand Manifold LH Steering Cyl Inner 2
8 Left Hand Manifold LH Steering Tie Inner 2
9 Left Hand Manifold RH Steering Tie Inner 2
10 Left Hand Manifold Steering Center Lever Pin 2
11 Left Hand Manifold RH Steering Cyl Inner 2
1 Right Hand Manifold Upper Suspension Cyl 0
2 Right Hand Manifold Rear A-Arm 2
3 Right Hand Manifold Front A-Arm 2
4 Right Hand Manifold Lower Suspension Cyl 0
5 Right Hand Manifold Steering Tie Outer 2
6 Right Hand Manifold Steering Cyl Outer 2
1 Rear Axle Manifold Upper Differential Link Front 4
2 Rear Axle Manifold Dump Body Pivot 0
3 Rear Axle Manifold Rear Upper Suspension Cyl 4
4 Rear Axle Manifold Rear Lower Suspension Cyl 4
5 Rear Axle Manifold Lower Differential Link Rear 4
6 Rear Axle Manifold Upper Differential Link Rear 4
7 Rear Axle Manifold Lower Differential Link Front 4
8 Rear Axle Manifold Dump Body Cyl Rod End Lower 0
9 Rear Axle Manifold Dump Body Cyl Rod End Upper 0
10 Rear Axle Manifold Dump Body Cyl Rod End Upper 0
11 Rear Axle Manifold Dump Body Cyl Rod End Lower 0
12 Rear Axle Manifold Lower Differential Link Front 4
13 Rear Axle Manifold Upper Differential Link Rear 4
14 Rear Axle Manifold Lower Differential Link Rear 4
15 Rear Axle Manifold Rear Lower Suspension Cyl 4
16 Rear Axle Manifold Rear Upper Suspension Cyl 4
17 Rear Axle Manifold Dump Body Pivot 0
18 Rear Axle Manifold Upper Differential Link Front 4

Installation
12 3A7633A
NOTE: Photographs may include optional equipment.
P-Clamp Weld Studs
Lower A-Arms
1. Install two (2) weld studs per A-Arm (FIG. 14).
2. Mark the location for the first of the weld studs, 8 in.
back from the grease point toward the tread plate,
and 1 in. down from the top of A-Arm (FIG. 15 and
FIG. 17).
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 (FIG.
16).
4. Clean the surface of paint and primer before welding
the studs (FIG. 17).
5. Weld the p-clamp studs into place.
6. Clean and paint the A-Arm surface with matching
Komatsu approved paint.
FIG. 14
FIG. 15
P-clamp
P-clamp
FIG. 16
FIG. 17

Installation
3A7633A 13
NOTE: Photographs may include optional equipment.
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 (FIG. 18 - FIG. 20).
2. Center one (1) weld stud under each of the dump
body support points, 2 in. down from the rectangular
structure, up to the pass-through-hole at the dump
body cylinder (FIG. 21).
3. Mark the location of the weld studs.
4. Clean surface of paint and primer before welding the
stud.
5. Weld the p-clamp studs into place.
6. Clean and paint the dump body surface and
p-clamp studs surface with matching Komatsu
approved paint.
FIG. 18
FIG. 19
13 inches
2 inches
Studs
13 inches
2 inches
FIG. 20
FIG. 21: Dump Body Cylinder

Installation
14 3A7633A
NOTE: Photographs may include optional equipment.
Remote Fill Manifold
Assembling the Manifold
1. Install 3/4 in. x 3/8 in. NPT reducer bushing and 3/8
in. x -6JIC fitting into the fill outlet port (FIG. 22).
2. Install the 3/8 in. x -6JIC fitting into the vent port
(FIG. 22).
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)
M12 bolts (FIG. 23).
2. Mount the assembled remote fill manifold to the
mounting bracket using the supplied 4 x 1/4-20
bolts, nuts and washers (FIG. 23).
3. Affix the remote filling instruction sticker above the
manifold on the frame (FIG. 22).
FIG. 22
FIG. 23

Installation
3A7633A 15
NOTE: Photographs may include optional equipment.
Compact Dyna-Star (CDS) Pump
Assembly
1. Remove the fill port and cover, optional outlet 1/4 in.
npt plug, and 3/8 in. npt refill vent plug.
2. Install a 3/8 in. npt, 90° street elbow (A) and a 3/8 in.
npt x -6JIC adapter (D) at the lubricant output con-
nection port, fill port, and refill vent port.
3. Install a 1/4 in. npt 90° street elbow (C) and the
pressure gauge (B) in the 1/4 in. npt port outlet.
Fitting Table
Pump Installation
1. Hoist the reservoir onto the right side deck plate of
the haul truck using the eye-bolt on the CDS pump
(FIG. 25).
2. Position the reservoir so the motor is facing the rear
of the truck. This is the deck area without slip resis-
tant texture. (FIG. 26).
FIG. 24
Ref Description Qty
a 3/8 in., 90° street elbow 3
b Gauge 1
c 1/4 in., 90° street elbow 1
d 3/8 npt to -6JIC adapter 3
A
A
A
D
D
C
B
LIFTING HAZARD
This equipment is heavy. Lifting or moving heavy
equipment incorrectly can cause serious injury such
as muscle strain or back injuries. To avoid injury:
• Do not lift or move this equipment without assis-
tance.
• Always use a lifting device secured to the pump lift
ring when moving or installing this equipment.
FIG. 25
FIG. 26
Eye-
bolt

Installation
16 3A7633A
NOTE: Photographs may include optional equipment.
3. Locate the reservoir mounting flange with the two
(2) mounting holes closest to the handrail, 10.0 in.
(354 mm) from the right hand side toe-kick plate
(FIG. 27 and FIG. 28).
4. Place the reservoir mounting flange so that the fur-
thest hole from step 3 measures 29.5 in. (149.3
mm) from the rear deck toe-kick plate (FIG. 29 and
FIG. 30).
FIG. 27
FIG. 28
FIG. 29
FIG. 30

Installation
3A7633A 17
NOTE: Photographs may include optional equipment.
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 (FIG.
31 and FIG. 32).
FIG. 31
FIG. 32

Installation
18 3A7633A
NOTE: Photographs may include optional equipment.
Pump Harness Extension
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.
2. Connect the Compact Dyna-Star pump cable to the
Compact Dyna-Star (FIG. 34).
3. Connect the Compact Dyna-Star extension harness
to the Compact Dyna-Star pump cable (FIG. 34).
4. Route the Compact Dyna-Star extension harness to
the hand rail, and down to the ladder brackets near
the toe board.
5. Route the extension cable toward the front of the
vehicle (FIG. 35).
6. Route the extension cable through the deck pass
and the grommet located in the right front corner of
the decking (FIG. 36).
FIG. 33
FIG. 34
FIG. 35
FIG. 36

Installation
3A7633A 19
NOTE: Photographs may include optional equipment.
7. The 12 wires connect below the decking around the
right front tire. The wires connect to an included
12-pin DT connector (FIG. 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.
9. Insert pins into connector according to Wiring Dia-
gram in GLC X Lubrication Controller manual.
10. Connect the pump harness extension to the GLC X
controller harness, see GLC X Cable Routing,
beginning on page 23.
FIG. 37
FIG. 38

GLC X Controller
20 3A7633A
NOTE: Photographs may include optional equipment.
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) (FIG. 39).
3. Install bracket fasteners (G) to the mounting bracket
(A) using bolts (B), washers (C) and nuts (D) as
shown in FIG. 40. Loosely fasten to allow for final
adjustment when installed to the equipment.
FIG. 39
45°
bend
a
g
g
45°
bend
FIG. 40
B
G
D
A
E
C