Graco Compact Dyna-Star 25P686 User manual

3A6932B
EN
Instructions
Compact Dyna-Star®
Auto-Fill Shut Off Kit
For use with Compact Dyna-Star Electric Pump to automatically stop filling Graco grease
tanks. For grease lubrication systems only. For professional use only.
Not approved for use in explosive atmospheres or hazardous (classified) locations.
Model
25P686 Auto-Fill Shut Off
25P687 Auto-Fill Shut Off with
Follower Plate
3500 psi (24.1 MPa, 241.3 bar) Maximum Working
Pressure
Related Manuals
3A6941 - Compact Dyna-Star Electric Pump Manual
333393 - Fill Valve
Important Safety Instructions
Read all warnings and instructions in this
manual and the Compact Dyna-Star
Pump instructions manual before using
the equipment. Save all instructions.

Contents
23A6932B
Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 5
Auto-Fill Shut Off Installation . . . . . . . . . . . . . . . . 5
Follower Plate Installation
(Part 25P687) . . . . . . . . . . . . . . . . . . . . . . . . 8
Auto-Fill Shut Off Overview. . . . . . . . . . . . . . . . . . 10
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fill/Refill the Tank . . . . . . . . . . . . . . . . . . . . . . . 11
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Technical Specifications . . . . . . . . . . . . . . . . . . . . 13
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 14

Warnings
3A6932B 3
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation 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.
.
WARNING
FIRE AND EXPLOSION HAZARD
When flammable fluids are present in the work area, such as gasoline and windshield wiper fluid, be
aware that flammable fumes can ignite or explode. To help prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources, such as cigarettes and portable electric lamps.
• Ground all equipment in the work area.
• Keep work area free of debris, including rags and spilled or open containers of solvent and gasoline.
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Use only grounded hoses.
•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment until
you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
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.

Warnings
43A6932B
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. See Technical Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Specifica-
tions in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete infor-
mation about your material, request Safety Data Sheet (SDS) from distributor or retailer.
• 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 manu-
facturer’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.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure and disconnect all power sources.
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. Protective equipment includes but is not
limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
WARNING

Installation
3A6932B 5
Installation
Pressure Relief Procedure
To relieve pressure in the system, use two wrenches
working in opposite directions on the pump outlet fitting
to slowly loosen the fitting only until no more lubricant or
air is leaking from the fitting (FIG. 1).
Auto-Fill Shut Off Installation
1. Disconnect power to the system (FIG. 2).
2. Relieve pressure in the system following the
Pressure Relief Procedure, see page 5.
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. 1
FIG. 2

Installation
63A6932B
3. Disconnect the main line from the pump outlet
(FIG. 3).
4. Loosen and remove the Compact Dyna-Star
Auto-Fill Shut Off plug. Dispose of the plug
according to local regulations (FIG. 4 and FIG. 5).
5. Grease the outside of the three (3) o-rings on the
Compact Dyna-Star Auto-Fill Shut Off cartridge
(FIG. 6).
6. Install the Compact Dyna-Star Auto-Fill Shut Off
cartridge (FIG. 6).
FIG. 3
FIG. 4
FIG. 5
FIG. 6
O-rings

Installation
3A6932B 7
7. Tighten the Compact Dyna-Star Auto-Fill Shut Off
cartridge (torque 45-55 ft-lb/61-74.5 N•m) (FIG. 7).
8. If the system currently has a follower plate,
installation is complete. For systems without a
follower plate, see Follower Plate Installation
(Part 25P687), page 8.
9. Use two wrenches working in opposite directions on
the pump outlet fitting to tighten (FIG. 1).
10. Reconnect the main line (FIG. 8).
11. Reconnect the power to the system (FIG. 9).
FIG. 7
FIG. 8
FIG. 9

Installation
83A6932B
Follower Plate Installation
(Part 25P687)
1. Disconnect power to the system (FIG. 10).
2. Relieve pressure in the system following the
Pressure Relief Procedure, see page 5.
3. Remove the nuts, bolts and the lifting hook from the
top of the tank and retain (FIG. 11).
4. Lift the cover, tank gasket, and pump off of the tank
and set aside.
5. In a new installation, the center o-ring of the follower
plate and the tank walls should be greased to allow
for easier follower plate movement (FIG. 12).
6. Place the follower plate inside of the tank with the
follower plate top (marked “top”) facing upward (FIG.
12).
FIG. 10
FIG. 11
FIG. 12
Grease

Installation
3A6932B 9
7. Replace the cover, tank gasket, and pump on to the
tank (FIG. 13).
8. Replace the nuts, bolts, and lifting ring.
9. Tighten (torque 10-12 ft-lb/13.6-16.3 N•m).
10. Reconnect the main line to the pump outlet (FIG.
14).
11. Reconnect the power to the system (FIG. 15).
FIG. 13
FIG. 14
FIG. 15

Auto-Fill Shut Off Overview
10 3A6932B
Auto-Fill Shut Off Overview
The Compact Dyna-Star Auto-Fill Shut Off fills and refills grease tanks in an automatic lubrication system. As grease
is added to the tank, it pushes the follower plate to the top of the tank where the valve pin actuates and closes the
inlet fluid path.
Note:The remote fill station pump stalls (dead-heads) when the tank is full. If this does not occur, 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.
Key:
AA Remote fill station pump*
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]
JJ Supply hose*
V Auto-Fill Shut Off
V1 Auto-Fill Shut Off valve pin
Y Follower plate
KTank
*User provided
FIG. 16
AA
BB
CC
GG
HH
EE
FF
DD
JJ
V
K
Y
V1