Graco Compact Dyna-Star 25P686 User manual

3A6932B

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

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