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