Graco 77X542 User manual

333393D
EN
Instructions
Fill Valve
Refill manifold for use with Graco Auto-Fill Shut Off Valve only. For professional use only.
Part No.:
77X542
132230
5000 psi (34.4 MPa, 344.7 bar) Maximum Working
Pressure
Part No. 132230: 3000 psi (20.7 MPa, 206.8 bar)
Important Safety Instructions
Read all warnings and instructions in this
manual and in Electric DynaStar and Auto-Fill
Shut Off Valve Instruction manuals. Save all
instructions.

Warnings
2333393D
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.
+
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like
just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
•Do not point dispensing device at anyone or at any part of the body.
•Do not put your hand over the fluid outlet.
•Do not stop or deflect leaks with your hand, body, glove, or rag.
•Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing
equipment.
•Tighten all fluid connections before operating the equipment.
•Check hoses and couplings daily. Replace worn or damaged parts immediately.
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.
See Technical Specifications in all equipment manuals.
•Use fluids and solvents that are compatible with equipment wetted parts. See Technical Specifications in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your
material, request MSDS from distributor or retailer.
•Do not leave the work area while equipment is energized or under pressure.
•Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
•Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s
replacement parts only.
•Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety
hazards.
•Make sure all equipment is rated and 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, moving parts, and hot surfaces.
•Do not kink or over bend hoses or use hoses to pull equipment.
•Keep children and animals away from work area.
•Comply with all applicable safety regulations.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury,
hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:
•Protective eye wear, and hearing protection.
•Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturers.
WARNINGWARNINGWARNING
WARNING

Installation
333393D 3
Installation
Typical Installation
A Fill Valve
B Dyna-Star Pump
C Auto-Fill Shut Off Valve
D Auto-Fill Inlet
E Reservoir
F Reservoir Port (vent line)
G Remote Filling Station Reservoir
H Remote Filling Station Pump (pneumatic)
J *Supply Hose (user supplied)
K *Supply Hose (user supplied)
L Drain Hose
M Fill Stud
N Operating Instructions Label
P Fill Valve Outlet
Q Fill Valve Vent Port
R Filter (recommended if grease/environment is
contaminated)
*Supply hoses must be rated for a minimum 5000 psi (34.4 MPa, 344.7 bar) pressure. See Operation, page 5 for
additional information.
A
B
C
D
E
F
G
H
J
L
K
P
Q
M
N
R

Installation
4333393D
Fill Valve Component
Identification
A Fill Valve
M Fill Stud
N Instruction Label (not shown, see Typical Installation,
page 3)
P Fill Valve Outlet
Q Fill Valve Vent Port
R Pressure Relief Plunger
S Pressure Gauge
T Dust Cover (Yellow)
U Pressure Relief Valve
Installation
The reference letters used in the following instructions refer to
the Typical Installation diagram provided on page 3 and the
Component Identification illustration (FIG. 1).
1. Select the installation location. Be sure the installa-
tion location chosen is clean, flat and easily accessi-
ble
2. Orient the Fill Valve (A) as shown in FIG. 1. When
the Fill Valve is correctly oriented the Pressure
Gauge (S) will be located on the top of the Fill Valve
block and the Pressure Relief Valve (U) will be
located on the bottom of the block.
3. Use mounting dimensions provided on page 7 of
this manual to drill 4 mounting holes in the installa-
tion surface
4. Secure Fill Valve (A) to installation surface using 4
1/4 inch bolts.
5. Select a convenient location close to the valve to
adhere the Operating Instructions label (N)
(included with your valve).
NOTE: Clean the surface prior to installing the label
to remove contaminants such as dust, dirt, grease
and oil residue which could weaken or prevent
adhesion.
6. Connect Supply Hose (K) between the Auto-Fill
Shut Off Valve (C) and Fill Valve Outlet (P) port
marked with an “O”.
7. Connect a Drain Hose (L) between the Fill Valve
Vent Outlet (Q) port marked with a “V” and the Res-
ervoir Port (E/F).
FIG. 1
M
T
S
R
P
Q
A
U
To reduce the risk of serious injury from skin injection,
the Fill Valve (A) must be installed with the pressure
gauge (S) located on the top of the Fill Valve and the
pressure relief valve (U) pointing down as shown in FIG.
1.

Installation
333393D 5
Operation
The reference letters used in the following instructions
refer to the Typical Installation diagram provided on
page 3 and Component Identification on page 4.
1. Pull out and hold the Pressure Relief Plunger (R)
long enough to relieve line pressure between Fill
Valve (A) and Auto-Fill Shut Off Valve (C).
2. Verify that the Pressure Relief Plunger (R) is seated
and returned to the original position.
3. Verify that the Auto-Fill Shut Off pin is down, indicat-
ing it is reset (FIG. 2). See the Auto-Fill Shut Off
instruction manual.
4. Remove yellow Dust Cover (T) from Fill Coupler (M).
5. Connect Supply Hose (J) between the Remote Fill-
ing Stations Pump (H) and Fill Coupler (M) port
marked with an “I”.
6. Start Remote Filling Station Pump (H).
7. When Reservoir (E) is filled:
• the Remote Filling Station Pump (H) stalls
(dead-heads),
• the Auto-Fill Shut Off pin pops up as shown in
FIG. 3,
• the gauge pressure rises to the fill pump’s set
pressure.
NOTE: If the pump does not stall (dead-head) there is a
leak in the system.
NO
8. Turn off the Remote Filling Station Pump (H).
9. Pull out and hold the Pressure Relief Plunger (R)
long enough to relieve line pressure between Fill
Valve (A) and Auto-Fill Shut Off Valve (C) and
between Remote Filling Station Pump (H) and Fill
Valve (A).
10. Verify that the Pressure Relief Plunger (R) is seated
and returned to the original position.
NOTE: The length of time it takes to vent varies depend-
ing on the system design and installation. In some
installations it may be necessary to repeat Step 9 to
ensure pressure is relieved.
11. Disconnect Supply Hose (J) at Fill Coupler (M).
12. Replace yellow Dust Cover (T) over Fill Coupler (M).
The remote filling station pump stalls (dead-heads)
when the reservoir is full, causing the supply system
pressure to rise to the maximum output pressure
of the filling station pump. To help prevent equipment
damage or serious injury caused by pressurized fluid,
such as skin injection or injury from splashing fluid,
always use a remote filling station pump with a maxi-
mum output pressure of 5000 psi (34.4 MPa,
344.7 bar) and use supply hoses with a minimum
pressure rating of 5000 psi (34.4 MPa, 344.7 bar).
NOTICE
Failure to reset the Pressure Relief Plunger (R) could
lead to equipment damage.
FIG. 2
pin
down
FIG. 3
NOTICE
Failure to reset the Pressure Relief Plunger (R) could
lead to equipment damage.
pin
up

Troubleshooting
6333393D
Troubleshooting
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
To relieve pressure in the system, use two wrenches
working in opposite directions on valve outlet fitting to
slowly loosen fitting only until fitting is loose and no
more lubricant or air is leaking from fitting as shown in
FIG. 4.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop dispensing and before
cleaning, checking, or servicing the equipment.
FIG. 4
Problem Cause Solution
Refill pump slows down or stalls and
no output at the fill valve.
Auto-Fill Shut Off Valve has not
reset
Be sure to relieve pressure by pull-
ing the Pressure Relief Plunger (R)
(see Component Identification,
page 4).
Make sure Auto-Fill Shut Off valve
pin is down. See FIG. 2, page 5
and/or Auto-Fill Shut Off Valve man-
ual.

Troubleshooting
333393D 7
Technical Specifications
Recommended hose to reduce pressure drop: 3/4 inch ID, 20 feet (6.1 m) length for all lines.
California Proposition 65
Fill Valve
US Metric
77X542
Maximum fluid working pressure 5000 psi 34.4 MPa, 344.7 bar
Relief value 5000 psi + 10% 34.4 MPa, 344.7 bar + 10%
132230
Maximum fluid working pressure 3000 psi 20.7 MPa, 206.8 bar
Relief value 3000 psi + 10% 20.7 MPa, 206.8 bar + 10%
Maximum fluid flow 2 gpm 7.57 lpm
Outlet port size
Model 77X542, 132230 3/4 inch npt
Vent port size
Model 77X542, 132230 3/8 inch npt
Inlet ISO 7241-1, Series B standard hydraulic quick disconnect
1/4 inch coupling
Wetted parts zinc plated steel parts, seals: Buna-N
Dimensions See Dimensions and Mounting (below)
Weight 5.06 lbs 2.3 kgs
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.

All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 333393
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
November 2019
Dimensions and Mounting
Graco Information
For the latest information about Graco products, visit www.graco.com.
For patent information, see www.graco.com/patents.
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Phone: [phone] or Toll Free: 1-800-533-9655, Fax: [phone]