Graco Dyna-Star HP 77X202 User manual

3A3956D
EN
Instructions
Dyna-Star®HP
Pump System
Provides lubricant flow and pressure to operate a single line parallel automatic lubrication
system. For automatic lubrication systems only.
Not approved for use in European explosive atmosphere locations.
Models
77X202 - MODULE, EDS, HP, AFSO, LL, 60 lb
77X203 - MODULE, EDS, HP, AFSO, LL, 90 lb
77X402 - MODULE, EDS, HP, SP, AFSO, LL, 60 lb
77X403 - MODULE, EDS, HP, SP, AFSO, LL, 90 lb
24VDC, Injector module with pump, tube-in-tube, vent valve,
auto-fill shutoff, low level, 60 lb. or 90 lb. reservoir.
3500 psi (24.1 MPa, 241 bar) Maximum Working Pressure
5000 psi (34 MPa, 344.7 bar) Maximum Refilling Inlet Pres-
sure
Related Manuals
Important Safety Instructions
Read all warnings and instructions in this
manual, the Dyna-Star HP and HF Pump
instruction manual and all related component
manuals (listed below). Save all instructions.
Manual Description
332514 Dyna-Star HP and HF Pump
332518 Dyna-Star HP and HF Auto-Fill Shut
Off Kit
332519 Dyna-Star HP Vent Valve Kit
333393 Fill Valve
334998 Power Cable Kit
334999 Cable Harness Kit
3A2960 GLC2200 Lubrication Controller

Contents
23A3956D
Contents
Warnings ...................................................................3
Typical Installation: Injector System ...................... 5
Typical Installation: Series Progressive
System ................................................................6
Systems with Fill Valve in the Refilling Line .......... 7
Installation ................................................................. 8
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 8
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
System Configuration and Wiring . . . . . . . . . . . . 8
Fuses ............................................................. 8
Wire Connection Table .................................. 9
24 VDC With Signal Input ............................ 10
24 VDC With External Relay ....................... 10
Motor Control Board .................................... 11
Fault Table: Red LED (E) ............................ 12
Pump Control Operation .............................. 12
Current Control and Flow Motor
Control Settings . . . . . . . . . . . . . . . . . . . . . 12
Current and Flow Control Adjustment ......... 12
Reservoir Mounting . . . . . . . . . . . . . . . . . . . . . . 13
Pump (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pump Module Operation .............................. 13
Inlet and Outlet Components ....................... 13
Vent Valve (L) . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Refilling Line Requirements . . . . . . . . . . . . . . . 14
Refilling Pump (P) Requirements . . . . . . . . . . . 14
Low Level Sensor (T) . . . . . . . . . . . . . . . . . . . . 14
Auto-Fill Shut Off . . . . . . . . . . . . . . . . . . . . . . . . 16
Refilling the Reservoir . . . . . . . . . . . . . . . . . . . . 16
Refilling Systems without a Fill Valve ..........16
Refilling Systems with a Fill Valve (Z) .........18
Troubleshooting ..................................................... 20
Parts List: ................................................................ 22
Accessories ................................................. 22
Technical Specifications ........................................ 23
Dimensions ............................................................. 24
Notes ........................................................................ 25
Graco Standard Warranty ...................................... 26
Graco Information .................................................. 26

Warnings
3A3956D 3
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.
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
43A3956D
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.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
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.

Typical Installation: Injector System
3A3956D 5
Typical Installation: Injector System
Systems with Pressure Relief Valve in the Refilling Line
The installation shown is only a guide for selecting and installing system components. Contact your Graco distributor
for assistance in planning a system to suit your needs. NOTE: The remote filling station pump stalls (dead-heads)
when the reservoir is full. If the pump does not stall (dead-head) there is a leak in the system.
Key:
A Lubricant outlet connection (marked with an “0”)
B Pump
C Ignition switch
C1 Fuse
D High-pressure lubricant supply lines
E Injector banks
F Lubrication controller
G Fill port (not used with Auto-Fill Shut Off)
H Overflow port (not used with Auto-Fill Shut Off)
J Breather
K Reservoir
L Vent Valve
M Motor
N Fluid overflow container
P Pump - remote filling station
R Reservoir - remote filling station
S Auto-Fill Shut Off
T Low Level Sensor
U Pressure Relief
V Supply Hose
FIG. 1
E
D
C
F
B
H
J
K
L
A
M
N
P
R
S
T
UV
C1
G

Typical Installation: Series Progressive System
63A3956D
Typical Installation: Series Progressive System
The installation shown below is only a guide for selecting and installing system components. Contact your Graco dis-
tributor for assistance in planning a system to suit your needs.
Key:
A Lubricant output connection (marked with an “0”)
BPump
C Ignition switch*
D High-pressure lubricant supply lines*
E Primary metering device*
F Lubrication controller*
G Fill port (not used with Auto-Fill Shut Off)
H Overflow port (not used with Auto-Fill Shut Off)
J Breather
K Reservoir / Tank
L Series Progressive metering device
MMotor
N Bearing
P Auto-Fill Shut Off
*User provided
FIG. 2
E
D
C
F
B
H
G
FrontBack
J
K
A
M
L
N
N
L
N
N
P

Systems with Fill Valve in the Refilling Line
3A3956D 7
Systems with Fill Valve in the Refilling Line
The installation shown is only a guide for selecting and installing system components. Contact your Graco distributor
for assistance in planning a system to suit your needs. NOTE: The remote filling station pump stalls (dead-heads)
when the reservoir is full. If the pump does not stall (dead-head) there is a leak in the system.
Key:
P Pump - remote filling station
R Reservoir - remote filling station
V Supply Hose
W Pressure Relief Line
Y Instruction Label
Z Fill Valveu
Z1 Pressure Relief Knob
AA Refilling Line
BB Filter
NOTE: The components highlighted in FIG. 3 identify the
unique features in a Fill Valve installation. See Typical Installa-
tion on page 5 for a complete list of the other system compo-
nents.
Install the fill valve (Z) in an easily accessible location between
the remote fill station pump (P) and Auto-Fill Shut Off Valve
(S).
The fill valve is used to relieve pressure in the refilling line and
to reset the Auto-Fill Shut Off.
FIG. 3
V
Y
Z
Z1
W
AA
P
R
BB

Installation
83A3956D
Installation
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 pump 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.
Grounding
System Configuration and Wiring
NOTE: Cable wiring harness kits are available from
Graco. See Parts page 22 for a complete list of available
kits.
Fuses
NOTE: The pump is equipped with a 6-pin (4 pins are
used), M23 connector for use with Graco cable wiring
harness kit 77X546. See Parts page 22.
FIG. 5 shows the pump connections when used with
Graco Wire Harness 77X546. Also see pages 10 and 11
for connection details when a customer/user supplied
wiring harness is used.
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 Pro-
cedure when you stop dispensing and before clean-
ing, checking, or servicing the equipment.
FIG. 4
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 electrical current.
NOTICE
Fuses (user supplied) are required on all models. To
avoid equipment damage:
• Never operate the Dyna-Star Pump models 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 35A fuses.

Installation
3A3956D 9
Pump Connection with Graco Wiring Harness 77X546
Wire Connection Table
FIG. 5
See FIG. 6
Pin Wire Color Connection
1 Orange Signal +
2 Black Power -
4RedPower+
5 Blue Signal -
FIG. 6

Installation
10 3A3956D
User Supplied Wiring Harness
24 VDC With Signal Input
*A Vent Valve is only used in an injector-based system.
24 VDC With External Relay
*A Vent Valve is only used in an injector-based system.
FIG. 7: Pump control switch shown in signal mode
FIG. 8: Pump controls switch shown in power mode

Installation
3A3956D 11
Motor Control Board
Key
A + (Positive) Power Input
B - (Negative) Power Input
C Turn On Signal -
D Turn On Signal +
E Red (Fault) LED - Blinks type of fault (See Fault Table)
F Green (Power) LED -
•Blinks: Power ON, Pump running
•Solid: Power/Pump OFF
G Current Control Potentiometer (Minimum: Turn Knob
Counter-Clockwise / Maximum: Turn Knob Clockwise)
H Flow Control Potentiometer (Minimum: Turn Knob
Counter-Clockwise / Maximum: Turn Knob Clockwise)
J Pump Control Switch*
•PWR - Turns pump on when power is applied
•SIG - Turns pump on when voltage is applied to:
- SIG IN -
- SIG IN +
K Blue Motor Wire Connection
L Yellow Motor Wire Connection
M Green Motor Wire Connection
N J5 Connector - Motor Hall Cable Connector
*NOTE: Be sure power to pump is OFF before switching
between the PWR and SIG modes.
FIG. 9
H
J
B
A
C
D
FE
G
KL
M
N

Installation
12 3A3956D
Fault Table: Red LED (E)
Pump Control Operation
• When the pump control switch (J, FIG. 9 page 11) is
set in signal mode, the motor/pump runs when volt-
age is applied to the signal and power connectors.
• When the pump control switch (J, FIG. 9 page 11) is
set in power mode, the motor/pump runs when volt-
age is applied to the power connectors. The signal
connectors do not require voltage.
Current Control and Flow Motor
Control Settings
Current and Flow Control Adjustment
1. Remove screws (a), cover (b) and gasket (c) to
access the control board (FIG. 10).
2. Current and Flow control are adjusted on the Motor
Control Board using the Current Control Potentiom-
eter Knob (G) and the Flow Control Potentiometer
Knob (H) (page 11). The Current Control knob (G)
governs pump speed, which in turn governs flow.
The Current setting has precedence over the Flow
Rate setting. You may be limited in achievable Flow
Rate by the Current setting.
Turn knob clockwise to increase setting value.
• Turn knob counter-clockwise to decrease set-
ting value.
NOTE: Values are based on lab test conditions at ambi-
ent temperature 72°F (22°C) with an input voltage of
24V. Actual results may very and should be verified in
the application.
3. Replace gasket (c) and cover (b) and screws (a),
being careful not to pinch any wires. Tighten bolts
securely. Torque bolts to 17-19 ft.-lbs (23-26 N.m).
Fault Blinks
Over Current 1
Locked Rotor 2
Low or High Voltage 3
High Motor temp 4
Missing Temp Sensor 5
High Board Temp 6
Bad Hall Cable 7
NOTICE
To avoid equipment damage, remove power before
switching modes from signal to power or power to sig-
nal.
FIG. 10
Current Flow
a
b
c
15
8
230
23
Amps
10
5
220
15
in
3
/min.

Installation
3A3956D 13
Reservoir Mounting
1. Mount Reservoir (K) on sturdy, flat surface with 6
(six) 3/8 inch diameter bolts. Note location of Fill
Port (G), Overflow port (H), and Low Level (T) and
Lubricant Outlet Connection (A) for easy access
once installed.
2. Connect High Pressure Lubricant Supply Line (D) to
the Lubricant Outlet Connection (A).
3. Ground system (see Grounding). Mount reservoir
to grounded chassis member.
Pump (B)
Pump instructions are provided in the Dyna-Star HP or
HF Pump instruction manual 332514 provided with your
system.
Pump Module Operation
The pump module provides lubricant flow and pressure
to operate a single line parallel automatic lubrication
system.
The module requires an electrical power supply and a
timed signal from a lubrication controller (F). Based on
these signals, the pump module provides lubricant flow
and pressure to operate the injectors (E) and vents the
injector system to reset the indicators.
1. At the start of the cycle, the lubrication controller (F)
initiates a signal, closing the vent valve (L) and start-
ing the pump (B).
2. The pump (B) builds pressure in supply line (D) until
all the injectors have actuated. Then the pressure
switch sends a signal to the lubrication controller
(F), ending 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 in the supply line (D) is relieved back into
the reservoir, resetting all injectors (E).
Inlet and Outlet Components
Vent Valve (L)
The vent valve is used to reduce system pressure and
allow the injector to reset. When energized, the valve
closes and holds pressure through the outlet port
(marked “0”) on the vent valve. When de-energized, it
vents pressure internally to tank.
Refer to the Dyna-Star HP or HF Vent Valve Kit manual
332515 for installation and operation instructions.
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. See
Technical Data, page 23 for pump weight. COMPONENT RUPTURE HAZARD
The maximum working pressure of the inlet and outlet
components in the system vary. Over-pressurizing an
inlet or outlet can cause it to rupture resulting in prop-
erty damage and 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
14 3A3956D
Refilling Line Requirements
To relieve the stall pressure in the refilling line a pres-
sure relief valve (U) (FIG. 1, page 5) or a fill valve (Z)
(FIG. 3, page 7) must be installed in the system.
Systems without Fill Valve
A pressure relief valve (U) and overflow container (N) for
collecting excess fluid that drains during pressure relief,
must be installed in an easily accessible location
between the remote filling station pump (P) and the
Auto-Fill Shut Off (S). This pressure relief valve is used
to relieve pressure in the refilling line and to reset the
Auto-Fill Shut Off. See Typical Installation, page 5.
A Pressure Relief Kit: 247902 is available from Graco.
Contact your distributor or Graco Customer Service for
additional information about this kit.
Systems with Fill Valve (Z)
Install the fill valve (Z) in an easily accessible location
between the remote fill station pump (P) and Auto-Fill
Shut Off Valve (S). See Typical Installation, page 7.
The fill valve is used to relieve pressure in the refilling
line and to reset the Auto-Fill Shut Off. See the Fill Valve
instruction manual 333393. Graco fill valve, part no.
77X542 is available. Contact your local Graco distribu-
tor.
Refilling Pump (P) Requirements
Low Level Sensor (T)
When grease is present the LED is green. When the
lubricant level in the reservoir reaches approximately
30% (low level), the LED turns to an amber color. (See
FIG. 11 and the Table below).
NOTE:
• At 30% capacity, the amber low level signals the
tank is reaching a point where the operator should
refill the tank. There is still lubricant in the tank and
immediate shutdown is not required.
• If your are using a GLC2200 (part number 24N468,
Series F or later only), the system will enter a low
level warning condition (LL03) after the switch input
is closed for more than 1 second. The pump contin-
ues to operate.
Keep the sensor protective cover (11b, page 19)
installed to prevent sensor damage.
Low Level Sensor Wiring instructions begin on page 15.
NOTE: Graco GLC2200 (part number 24N468, Series F
or later only) can be used to run the pump and monitor
the low level. Refer to FIG. 13 for Low Level Sensor wir-
ing in systems controlled with a GLC2200. A Low Level
Sensor cable (part number 129072) and a GLC2200
Wiring Harness (part number 24P314) are required.
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
maximum output pressure of 5000 psi (34 MPa,
344.7 bar) and use a refill line with a pressure rating
equal to or greater than the refill pump.
Condition LED
COLOR
Out 2 (Pin #2)
(See FIG. 13, page 15)
Grease Present Green 0 VDC
No Grease
Present Amber 24 VDC
FIG. 11
LED Light
Cover

Installation
3A3956D 15
Low Level Sensor Wiring with GLC2200 Lube Controller
FIG. 12
FIG. 13
FIG. 14
Pin Connector
6LC-4400

Installation
16 3A3956D
Auto-Fill Shut Off
The Auto-Fill Shut Off (S) is used for refilling the grease
tank/reservoir in an automatic lubrication system. When
the grease level in the tank is full, the Auto-Fill Shut Off
automatically ends the filling operation. Refer to the
Auto-Fill Shut Off Kit instruction manual 332518 for com-
plete instructions and additional information.
Always fill tank full when refilling tank.
NOTE: For systems without a fill valve, see Refilling
Systems without a Fill Valve instructions beginning on
page 16. For systems with a fill valve, see Refilling Sys-
tems with a Fill Valve beginning on page 18.
As grease is added to the reservoir, it pushes the dia-
phragm (5b, page 22) up to the top of the reservoir. The
diaphragm then pushes the valve pin and closes the
inlet fluid path.
When the fluid refilling path closes, the refilling line pres-
surizes and brings the refilling pump to a pressurized
stall condition.
NOTE: The operator must monitor system while filling
tank to reduce accidental fluid overflow.
Refilling the Reservoir
Refilling Systems without a Fill Valve
1. Connect lubricant supply hose (V) from remote fill-
ing station pump to the Auto-fill Shutoff Inlet (FIG. 1,
page 5).
2. Turn on remote filling station pump (P) and fill reser-
voir (K) until the indicator pin on the Auto-Fill Valve
(S) pushes up as shown in FIG. 15; pressure in the
refilling pump (P) builds and the pump stalls.
3. Turn off air supply to refilling pump (P).
FIG. 15
pin
up
S

Installation
3A3956D 17
4. Relieve pressure between the remote filling station
pump (P) and the Auto-Fill Shut Off (S):
a. Open ball valve (bv) (FIG. 16). Pressure will be
released and excess fluid will drain out of the
drain tube (dt) and into the lubrication collection
container (N).
b. Close ball valve (bv) when all pressure has
been relieved.
NOTE: The pin may not drop and the Auto-Fill
Shut Off may not reset because the tank is full.
However, when the pump begins using the
grease, the pin resets. The pin must reset
before the next cycle of refilling.
5. Disconnect lubrication supply hose from Auto-Fill
(S).
6. Install plugs in the Auto-Fill Shut Off inlet and the
refilling line (V) to prevent contaminants from enter-
ing the pump.
FIG. 16: In line installation shown
bv
G
dt
H
FIG. 17
pin
drops

Installation
18 3A3956D
Refilling Systems with a Fill Valve (Z)
The reference letters used in the following instructions
refer to the Typical Installation diagrams provided, FIG.
3, page 7.
1. Prior to starting the fill, pull out and hold black Pres-
sure Relief Knob (Z1) long enough to relieve line
pressure between Fill Valve (Z) and Auto-Fill Shut
Off Valve (S).
2. Verify the Auto-Fill Shut Off (S) pin is down, indicat-
ing it is reset (FIG. 19).
3. Remove yellow dust cover (Z2) from fill coupler (Z3)
(FIG. 18).
4. Connect refilling line (AA) between the remote filling
stations pump (P) and fill coupler (Z3) port marked
with an “I” (FIG. 18).
5. Start remote filling station pump (P).
6. When reservoir (K) is filled:
• the Remote filling station pump (P) stalls
(dead-heads),
• Auto-Fill Shut Off (S) pin pops up see FIG. 20,
• the gauge pressure in the refilling lines (V and
AA) rises to the fill pump’s set pressure.
NOTE: If the pump does not stall (dead-head) there is a
leak in the system.
FIG. 18
Z1
Z2
Z3
FIG. 19
FIG. 20
pin
down
pin
up

Installation
3A3956D 19
7. Relieve pressure between remote filling station
pump (P) and the fill valve (Z):
a. Turn off the remote filling station pump (P).
b. Pull out and hold black pressure relief knob (Z1)
long enough to relieve line pressure between fill
valve (Z) and Auto-Fill Shut Off Valve (S) and
between the remote filling station pump (P) and
fill valve (Z).
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 b to
ensure pressure is relieved.
c. Disconnect the refilling line (AA) at the fill cou-
pler (Z3).
d. Replace the yellow dust cover (Z2).
Service
Use only Genuine Graco Repair Parts.
See separate system component manuals for service
instructions. For pump service see manual 332514. For
vent valve service see manual 332519.

Troubleshooting
20 3A3956D
Troubleshooting
Problem Cause Solution
Pump (B) is not running; i.e., not
cycling, there is no lubricant output,
pump runs slow, the control board’s
red LED fault is illuminated, etc.
Pump (B) malfunction. Refer to the pump manual 332514.
Lubricant is leaking from pressure
relief.
Blockage in the line. Check for blockage in the line. Clear
blockage.
Pressure switch not actuated/mal-
functioning.
Check switch wiring
Replace pressure switch
Pressure switch set too high. Reduce system pressure
Lubricant coming out of breather (J). Reservoir (K) overfilled because
Auto-Fill Shut Off (S) did not shut the
refilling line (D).
Replace the Auto-Fill Shut Off dia-
phragm (5b) and Auto-Fill Shut Off
valve (5a). Refer to manual 332518.
Refilling pump (P) slows down or
stalls and no output at the fill valve
(Z).
Auto-Fill Shut Off Valve (S) has not
reset
Relieve all refilling line (AA) pres-
sure. see page 14.
Make sure Auto-Fill Shut Off (S) pin
is down. See FIG. 17, page 17.
Refilling pump (P) runs continuously
but does not stall.
Leakage in the system Inspect the refilling line (V) and cor-
rect any leaks.
Reservoir (K) overfilled because
Auto-Fill Shut Off (S) did not close
the refill line.
Replace the Auto-Fill Shut Off dia-
phragm (5b) and Auto-Fill Shut Off
Valve (5a). Refer to manual 332518.