Graco Dyna-Star 3A6941J User manual

3A6941J
EN
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.
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
Important Safety
Instructions
Read all warnings and instructions
in this manual and in your injector
manual before using the
equipment. Save these
instructions.

Table of Contents
2 3A6941J
Table of Contents
Pump Model Selection Matrix . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 6
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Single Line Parallel System ............................ 7
Series Progressive System.............................7
Inlet and Outlet Components. . . . . . . . . . . . . . . . 7
Vent Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . 8
Motor Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Motor Electrical Connection . . . . . . . . . . . . . . . . 8
Typical Installation: Single Line Parallel System . 9
Typical Installation: Series Progressive System. 10
Typical Wiring: Single Line Parallel Systems . . . 11
Component Identification . . . . . . . . . . . . . . . . . 12
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fill the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fill Pumps with an Auto-Fill Shut Off (AFSO). . . 15
Refill the Tank: Pumps with an Auto-fill
Shut Off (AFSO) ..................................... 16
Fill Pumps Without an Auto-fill Shut Off
(AFSO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Refill the Tank: Pumps without an Auto-fill
Shut Off..................................................18
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Priming the System . . . . . . . . . . . . . . . . . . . . . . 20
Pump Operation Overview. . . . . . . . . . . . . . . . . 20
Single Line Parallel System .......................... 20
Series Progressive System...........................20
Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Level Monitoring . . . . . . . . . . . . . . . . . . . . . . . . 21
Low Level Switch..........................................21
Level Transducer .......................................... 22
Pressure Switch............................................ 23
Pressure Transducer..................................... 23
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Disassemble. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Reassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Related Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Dimensions: Pump with Tank . . . . . . . . . . . . . . . . . . 48
Dimensions: Stand Alone Pump . . . . . . . . . . . . . . . . 49
Dimensions: Stand Alone Pump . . . . . . . . . . . . . . . . 50
Mounting Dimensions: Stand Alone Pump. . . . . . . . 51
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . 52
California Proposition 65 . . . . . . . . . . . . . . . . . . 53
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . . . 54
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Pump Model Selection Matrix
3A6941J 3
Pump Model Selection Matrix
Pump models are made up of a six-digit part number. The first two digits are fixed alpha characters, while the
remaining four are chosen from the matrix below. Select an item from each column to fill in the model number for
ordering.
Note: Some pump configurations are not available. Contact Graco customer service or your local Graco distributor
for assistance.
Pump Description Metering System Feedback Tank Tank Accessories
112L / 35 lb. Bucket
Length, 24 VDC
0Single Line Progressive,
no vent valve, no pressure
reporting
0No Tank,
Bare Pump
0No Tank,
Bare Pump
220L Tank Length,
24 VDC
1Vent Valve, No Pressure
Reporting
112L Steel Tank
with Follower
Plate
1Low Level Switch
360 lb. Tank Length,
24 VDC
2Vent Valve, Pressure
Switch
220L Steel Tank
with Follower
Plate
2Level Transducer
3Vent Valve, Pressure
Transducer
335 lb. Plastic
Bucket Kit
3Auto-Fill Shut Off and
Low Level Switch
412 L Steel Tank
with no Follower
Plate
4Auto-Fill Shut Off, Level
Transducer
520 L Steel Tank
with no Follower
Plate
660 lb. Steel
Tank with
Follower Plate
760 lb. Steel
Tank with no
Follower Plate
C D 123 4
123 4

Warnings
4 3A6941J
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.
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
3A6941J 5
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 in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See in all equipment man-
uals. Read fluid and solvent manufacturer’s warnings. For complete information about your mate-
rial, 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 man-
ufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and cre-
ate 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 equip-
ment, 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 manufac-
turer.
WARNING

Installation
6 3A6941J
Installation
Grounding
To ground the pump: remove the ground screw (Z)
located on the back of the gear box and insert it
through the eye of the ring terminal (W) at end of
ground wire (Y). Fasten the ground screw (Z) back onto
the pump and tighten securely. Connect the other end
of the ground wire (Y) to a true earth ground (FIG. 1). To
order a ground and wire clamp, order Part 222011.
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 the pump outlet
fitting to slowly loosen the fitting only until no more
lubricant or air is leaking from the fitting (FIG. 2).
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.
FIG. 1
Z
W
Y
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. 2

Installation
3A6941J 7
Fuses
Mounting
Note: Upper case letters used in the following
instructions refer to Typical Installation: Single Line
Parallel System (FIG. 5), Typical Installation: Series
Progressive System (FIG. 6), Typical Wiring: Single
Line Parallel Systems (FIG. 7), and Component
Identification (FIG. 8) diagrams starting on page 9.
Securely mount and ground the unit before operation.
1. Mount the tank (K) on a sturdy, flat surface with
user-provided bolts. Install so that the fill port (F)
and the lubricant outlet connection (P or AC) are
easily accessible after installation.
2. Connect the controller (F) (if used).
3. Connect a high pressure lubricant supply line (D) to
the lubricant outlet connection (P or AC).
4. Connect all electrical connections. See Typical
Wiring: Single Line Parallel Systems diagram,
page 11.
5. Ground the system. See Grounding instructions,
page 6.
Pump
The pump provides lubricant flow and pressure to oper-
ate an automatic lubrication system.
Single Line Parallel System
The pump requires an electrical power supply and a
timed signal from a lubrication controller (F). The pump
provides lubricant flow and pressure to operate the
injectors (E), and vents the injector system to reset the
injectors.
Series Progressive System
The pump requires an electrical power supply and a
timed signal from a lubrication controller (F). The pump
provides lubrication flow and pressure to operate
metering devices (AD).
Inlet and Outlet Components
NOTICE
Fuses (user supplied) are required on all models. To
avoid equipment damage:
• Never operate the pump without a fuse installed.
• A fuse of the correct voltage and amperage must
be installed in line with the power entry to the sys-
tem. Graco recommends using a 10A time delay
fuse.
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
when moving or installing this equipment. See
Technical Specifications, page 52 for pump
weight.
The breather (J) vents the tank to the atmosphere. If it
is plugged the tank will over-pressurize and rupture.
Be sure the breather is not plugged before filling the
pump.
COMPONENT RUPTURE HAZARD
The maximum working pressure of the inlet and out-
let components in the system vary. Over-pressurizing
an inlet or outlet can cause components to rupture,
potentially resulting in serious injury such as skin
injection or injury from splashing fluid. To reduce the
risk of component rupture:
• Be sure to know the maximum working pressure
of each inlet and outlet component in the system.
•Never exceed the maximum working pressure of
the inlet and outlet components.

Installation
8 3A6941J
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).
Motor Details
The pump (B) is driven by a 24 V DC brushless motor (1)
with a built-in controller. The motor LED flashes
multiple times during start up and stays on during
operation. Refer to Troubleshooting, page 40 for more
information.
Motor Electrical Connection
FIG. 3
B
1
FIG. 4

Installation
3A6941J 9
Typical Installation: Single Line Parallel System
Key:
A Lubricant output connection*
B Pump
C Ignition switch*
D High-pressure lubricant supply lines*
E Injector banks*
F Lubrication controller*
G Fill port
H Overflow port
K Tank
L Vent Valve
NN Bearing*
*User provided
FIG. 5
A
B
C
D
E
F
G
H
K
NN
L

Installation
10 3A6941J
Typical Installation: Series Progressive System
Key:
A Lubricant output connection*
B Pump
C Ignition switch*
D High-pressure lubricant supply lines*
F Lubrication controller*
G Fill port
H Overflow port
K Tank
NN Bearing*
AD Metering device*
*User provided
FIG. 6
A
B
D
NN
F
AD
K
H
G
C
NN
NN
NN

Installation
3A6941J 11
Typical Wiring: Single Line Parallel Systems
FIG. 7

Installation
12 3A6941J
Component Identification
Key:(Figure 6)
B Pump
G Fill port and cover
H Overflow port
J Breather
K Tank
L Vent valve
M Motor
N Pressure relief valve
P Outlet (3/8 in. NPT)
R Gear box
S Low level switch or level transducer
T Pressure switch or transducer
U Lift ring
V Auto-fill shut off (AFSO) (optional)
Y Follower plate
Z Tube-in-tube
AB Plug to check venting / pressure relief
AC Refill vent plug or refill pressure relief
AD Outlet (1/4 in. NPT) (optional)
FIG. 8
AB
PL
VM
N
T
S
U
J
K
Z
Y
H
G
AC
R
B
AD
U
V

Setup
3A6941J 13
Setup
Fill the Tank
The fill port is used for filling and refilling the tank for
pumps with or without auto-fill.
Fill the tank through the fill port (FIG. 9).
Auto-Fill Shut Off: When grease is added, the follower
plate is pushed upward and closes the flow path. (FIG.
10).
Non-Auto-Fill Shut Off: When grease is added, the
follower plate is pushed upward. When the tank is full,
the grease will begin to flow out of the overflow port (H).
FIG. 9:
Fill Port
FIG. 10
Follower
Plate

Setup
14 3A6941J
Always fill the pump through the fill port to expel any air
from the tube-in-tube (FIG. 11).
Always use the follower plate to prime the pump for
grease NLGI 1, NLGI 2, and for cold pumping
applications.
Note: The auto-fill shut off requires using a follower
plate.
The follower plate should not be used with oil and low
viscous grease applications. The follower plate may
sink in these lubricants and block the pump inlet.
FIG. 11
Tube-in-Tube

Setup
3A6941J 15
Fill Pumps with an Auto-Fill Shut Off (AFSO)
Note: The remote filling station pump stalls (dead-heads) when the tank is full. If the pump does not stall
(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.
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*
K Tank
V Auto-Fill Shut Off
V1 Auto-Fill Shut Off valve pin
Y Follower plate
*User supplied
NOTICE
Never allow the pump to run dry of the fluid being
pumped to avoid pump damage.
NOTICE
If the refilling pump runs dry it pumps air into the
pump and may cause damage. Always make sure
that there is enough lubricant in the refilling pump
station.
FIG. 12
AA
BB
CC
GG
HH
EE
FF DD
JJ
V
K
Y
V1

Setup
16 3A6941J
The auto-fill shut off (V) is used to refill the grease tank
(K) in an automatic lubrication system. When the grease
level in the tank is full, the auto-fill shut off automatically
ends the filling operation.
Always fill the tank (K) to full during refilling.
As grease is added to the tank (K), the follower plate (Y)
is pushed to the top of the tank (K) and pushes up the
valve pin (V1) which closes the inlet fluid path. Pin (V2)
pops up when the tank is full (FIG. 13).
When the fluid refilling path closes, the refilling line (GG)
pressurizes and brings the remote fill station pump (AA)
to a pressurized stall condition.
Note: The operator must monitor the system during fill-
ing of the tank to prevent any accidental fluid overflow.
Refill the Tank: Pumps with an Auto-fill
Shut Off (AFSO)
1. Pull and hold the fill valve pressure relief knob (FF)
long enough to relieve line pressure between the fill
valve (EE) and the auto-fill shut off valve (V).
2. Verify the auto-fill shut off pin (V2) is down, indicat-
ing it is reset (FIG. 14).
3. Remove the dust cover (DC) from the fill coupler
(FC) on the fill valve (EE) (FIG. 15).
FIG. 13
The breather (J) vents the tank to the atmosphere. If it
is plugged the tank will over-pressurize and rupture,
potentially causing serious injury. Be sure the
breather is not plugged before filling the pump.
V2
FIG. 14
FIG. 15
V2
Pin Down
EE
DC
FC
FF

Setup
3A6941J 17
4. Connect the supply hose (JJ) between the remote
fill station pump (AA) and fill coupler (FC) port
marked with an “I” (FIG. 15).
5. Start the remote fill station pump (AA).
6. When the tank (K) is filled:
• The remote fill station pump (AA) stalls
(dead-heads),
• the auto-fill shut off pin (v2) pops up as shown
in FIG. 16,
• The pressure gauge needle 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
7. Turn off the remote fill station pump (AA).
8. Pull and hold the fill valve pressure relief knob (FF)
long enough to relieve line pressure between fill
valve (EE) and Auto-fill Shut Off Valve (V) and
between remote fill station pump (AA) and fill valve
(EE).
Note: The length of time it takes to vent the pressure
varies depending on the system design and installation.
In some installations it may be necessary to repeat Step
8 to ensure pressure is relieved.
9. Disconnect the supply hose (JJ) from the fill coupler
(FC) (FIG. 15).
10. Replace the dust cover (DC) over the fill coupler
(FC).
NOTICE
To prevent damage to the unit:
• Check breather (J) vent for proper operation
before filling the tank (K).
• Do not fill tank (K) beyond the overflow port (H).
• Do not use the breather (J) as a port to fill the tank.
FIG. 16
V2

Setup
18 3A6941J
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.
Key:
AA Remote fill station pump*
BB Remote fill station tank*
CC Filter*
DC Dust cap
G Fill port
JJ Supply hose*
H Overflow port
Y Follower plate
*User supplied
Refill the Tank: Pumps without an Auto-fill
Shut Off
FIG. 17
BB
AA CC
JJ
DC
G
H
Y
Do not insert your finger into the overflow port while
filling a tank equipped with a follower plate. Injury or
amputation could result.
COMPONENT RUPTURE HAZARD
The maximum working pressure of each component
in the system may not be the same. To reduce the
risk of over pressurizing any component in the
system, know the maximum working pressure of
each component. Never exceed the maximum
working pressure of the lowest rated component in
the system. Over pressurizing can result in rupture,
potentially resulting in serious injury from skin
injection or splashing fluids.
Regulate pressure to the pump so that no fluid line,
component or accessory is over pressurized.

Setup
3A6941J 19
1. Connect the lubricant supply hose (JJ) from the
remote filling station pump (AA) to the fill port (G)
(FIG. 18).
2. Slowly turn on the supply lubricant until the level of
lubricant reaches the overflow port (H). When the
tank (K) is full (or overfilled) grease will flow out of
the overflow port. (H).
Note: For pump tanks (K) with a follower plate (Y),
fill the tank until the follower plate reaches the
overflow port (H) and grease flows out.
FIG. 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. Be sure the
breather is not plugged before filling the pump.
NOTICE
To prevent damage to the unit:
• Check breather (J) vent for proper operation
before filling the tank (K).
• Do not fill tank (K) beyond the overflow port (H).
• Do not use the breather (J) as a port to fill the tank.
G

Operation
20 3A6941J
Operation
Note: Upper case letters used in the following
instructions refer to Component Identification,
Typical Installation: Single Line Parallel System and
Typical Installation: Series Progressive System
diagrams starting on page 9.
The unit must be securely mounted and grounded
before operation.
Priming the System
1. After the tank (K) is completely filled, remove the
high pressure lubricant supply line (D) from the out-
let.
2. Connect power to the pump (B).
3. Start the pump (B) and run until all of the air has
been expelled and fluid flow is continuous (FIG. 19).
4. Reconnect the high pressure lubricant supply line
(D) to the outlet.
Pump Operation Overview
Single Line Parallel System
1. At the start of the cycle, the lubrication controller (F)
initiates a signal that closes the vent valve (L) and
starts the pump (B).
2. The pump (B) builds pressure in the supply lines (D)
until all the injectors (E) actuate. Then the pressure
switch (T) sends a signal to the lubrication control-
ler (F) to end the cycle.
3. The lubrication controller (F) terminates the signal
to the pump (B) and power to the vent valve (L).
4. The vent valve (L) opens.
5. Pressure is relieved in the supply lines (D), back into
the tank (K), and resets all of the injectors (E).
Series Progressive System
1. At the start of the cycle, the lubrication controller (F)
initiates a signal to start the pump (B).
2. The pump (B) supplies lubricant and pressure to the
metering devices (AD). When the metering devices
are active, they carry lubricant to the lube points.
3. Continuous lubrication is provided during pump
operation.
4. To control lubrication based upon number of
cycles, a cycle switch can be added to the metering
devices.
Shutdown
For normal shut down, disconnect power to the
lubricator controller (F) and to the pump.
FIG. 19