Graco 309015B, Design Manual

Page 1: ...tructions Automatic Grease Lubrication Systems For Mobile Mining Equipment Table of Contents Description 2 Product Warnings and Cautions 6 Automatic Lube Definitions 9 System Components 10 Automatic Lubrication System Design Guide 14 System Installation 19 System Operation 22 Troubleshooting 24 Graco Phone Number 26 ...

Page 2: ...ubrication system The entire system consists of a pump module injectors and system controls The pump module provides the sys tem inherent pressurization and venting cycles to activate the injectors The injectors measure precise amounts of grease to be dispensed to individual bearing points during an automatic lube cycle The controls consist of a timer and a solenoid operated valve which turn the p...

Page 3: ...3 309015 Notes ...

Page 4: ...er Supply air or hydraulic air power is shown Fig 1 A KEY Fig 1 A Pump power supply B Regulator C Solenoid valve D Pump module E Ignition switch F Power supply valve bleed type valve is required in air systems G Supply line H Injectors J Timer controller K Battery L Gauge M Bearings N Quick disconnect air coupler P Feed lines R Ground wire S Branch lines B C D G H J E F K L M N P R S 9656A ...

Page 5: ...Lubricant output connection D Pump module E Ignition switch F 3 Way solenoid valve G High pressure lubricant supply lines H Injector banks J Lubrication controller K Fill port L Overflow port M Breather N Flow control valve FCV P Reservoir R Ground wire for non mobile installation S Pressure reducing valve PRV T Hydraulic tank line U Vent valve V Vent line W Follower plate optional X High pressure...

Page 6: ...ge call your Graco distributor Do not alter or modify this equipment Use only genuine Graco parts and accessories Check equipment daily Repair or replace worn or damaged parts immediately Do not exceed the maximum working pressure of the lowest rated system component Use fluids and solvents which are compatible with the equipment wetted parts Refer to the Tech nical Data section of all equipment m...

Page 7: ...clogs and before you clean or service this equipment Tighten all fluid connections before you operate this equipment Check the hoses tubes and couplings daily Replace worn or damaged parts immediately Do not repair high pressure couplings you must replace the entire hose Fluid hoses must have spring guards on both ends to protect them from rupture caused by kinks or bends near the couplings TOXIC ...

Page 8: ...and correct the problem Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being dispensed Keep the dispensing area free of debris including solvent rags and gasoline Do not smoke in the dispensing area MOVING PARTS HAZARD Moving parts such as the air motor piston can pinch or amputate your fingers Do not operate the pump with the air motor plates remo...

Page 9: ...igned system Vented The state of the injector after pressure is relieved at the inlet It also means the measured amount of grease is fully transferred to the dispensing chamber of the injector Main supply line The line that supplies lubricant from the pump module to the injector groups or banks Branch supply line The line that branches off the main supply line to feed individual injector banks The...

Page 10: ...he pump module The solenoid operates on a 24 volt signal received from the timer The solenoid also has a manual override button to activate the pump module Pressure switch optional 9146A A pressure switch can be installed in an automatic lube system for additional system control and safety A normally open pressure switch when properly connected to the timer and installed so that it monitors supply...

Page 11: ... factory set at 4000 psi and is non adjustable Reservoir The primary function of the reservoir is to contain the lubricant intended for later dispensing into the bearings The reservoir has several features The vent line is external to the reservoir to allow for trouble free follower plate op eration The fill port of the reservoir is at the bottom of the reservoir and is specifically designed such ...

Page 12: ...for a single injector can not be split into multiple bearing points The injectors come in various mounting configurations as shown below For details of injector operation refer to page 23 Manifold mounted 9061A Manifold 1 to 5 injectors mounted on a common inlet manifold Up to 5 injector outputs can be combined for dispense to a common bearing point with a large grease requirement using a cross ov...

Page 13: ... Lines Main supply line Line that supplies lubricant from the pump module to the injector groups or banks Branch supply line Line that branches off the main supply line to feed individual injector banks Prevents system venting problems in cold weather by minimizing the amount of grease vented through the injector manifolds Feed line Line that supplies lubricant from injectors to bearings ...

Page 14: ...ppropriate Volume Chart page 16 to determine the bearing lubricant volume for each point based on the bearing dimension Record the volume on the System Worksheet NOTE The Volume Charts use an assumption of a 0 002 film thickness of lubricant to calculate the bearing lubri cant volume Step 3 Determine number of injectors per point injector setting and timer setting Using the Injector and Timer Sett...

Page 15: ... Use the Injector and Timer Setting Chart page 17 to fill out the injector settings and timer settings Lube Pt Description Journal Flat Roller Results from Tables Pt p Length in Dia in Length in Width in Shaft Dia in No of Rows Vol ume cu in No of Inj Inj Setting 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Fill in the pause interval here minutes ...

Page 16: ... 0 01 0 01 0 02 0 02 0 02 0 02 0 02 0 03 0 03 0 03 0 03 0 03 0 04 0 04 0 04 0 04 0 04 0 05 0 05 2 0 00 0 01 0 01 0 02 0 02 0 02 0 03 0 03 0 04 0 04 0 04 0 05 0 05 0 06 0 06 0 06 0 07 0 07 0 08 0 08 0 08 0 09 0 09 0 10 3 0 01 0 01 0 02 0 02 0 03 0 04 0 04 0 05 0 05 0 06 0 07 0 07 0 08 0 08 0 09 0 10 0 10 0 11 0 11 0 12 0 13 0 13 0 14 0 14 4 0 01 0 02 0 02 0 03 0 04 0 05 0 06 0 06 0 07 0 08 0 09 0 1...

Page 17: ...ber of injectors Turns number of turns from maximum setting 15 Minutes Injectors 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Minutes Turns 8 8 7 7 7 6 6 6 5 5 5 4 4 4 3 3 3 2 2 1 20 Minutes Injectors 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 Minutes Turns 8 8 7 7 6 6 5 5 4 4 3 3 2 2 2 1 1 0 0 4 30 Minutes Injectors 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 Minutes Turns 8 7 6 6 5 4 4 3 2 2 1 0 4 4 3 3 3 2...

Page 18: ...49 wall thickness or 1 2 in Schedule 40 pipe Steel tubing must be soft annealed D O M welded or seamless hydraulic fluid line tubing Feed line recommendations Up to 17 ft maximum hose length 3000 psi minimum working pressure 1 4 in ID hose Up to 26 ft maximum hose length 3000 psi minimum working pressure 3 8 in ID hose Step 5 Determine bill of material From the original layout sketch determine how...

Page 19: ...in power supply line to pump module Connect leads to timer output Do not ground leads on Graco timer 115123 refer to manual 308950 Connect either lead to the output on timer and the other lead to the output on timer Pressure switch optional For pressure shutoff systems Can be installed in grease supply line for using higher pump pressures Refer to instruction manual 308950 for electrical hookup 1 ...

Page 20: ...cant outlet 1 2 in nps swivel Hydraulic high pressure inlet 3 8 in nps swivel 35 15 in 893 mm 15 0 in 381 mm Six 7 16 in 11 mm diameter holes on 13 7 8 in 352 mm bolt circle Overflow port 1 2 in npt Fill port 1 2 in npt Lubricant outlet 1 2 in nps swivel Hydraulic tank 3 4 in nps swivel Hydraulic high pressure inlet 3 8 in nps swivel Mounting Diagram Mounting Diagram 15 0 in 381 mm Dimensions Mode...

Page 21: ...hort as possible Connect to injector inlet 3 8 npt Injectors Description Dimension A Dimension B Injector GL 1 one point 2 48 in 63 0 mm Injector GL 1 two point 3 00 in 76 0 mm Injector GL 1 three point 1 25 in 31 7 mm 4 23 in 107 5 mm Injector GL 1 four point 2 50 in 63 4 mm 5 47 in 139 0 mm Injector GL 1 five point 3 75 in 95 1 mm 6 71 in 170 5 mm Injector GL 1 replacement Group injectors typica...

Page 22: ...lines Run the primed pump at reduced output pressure to slowly fill the supply lines with lubricant Remove the fitting at the end of each branch line to allow air to escape from the line 3 Bleed feed lines two methods a Disconnect the line from the bearing and cycle the automatic lubrication system until lubricant has filled all the lines b Disconnect the line from the bearing Using a grease gun a...

Page 23: ...ure forces the piston down pushing the lubricant from the discharge chamber through the outlet to the bearing Stage 3 At the bottom of its stroke the piston pushes the slide valve downward closing off the path to the measuring cham ber The piston and slide valve hold this position as long as the inlet lubricant remains under pressure Stage 4 As the lubricant inlet pressure is relieved the slide va...

Page 24: ...not build sufficient pres sure Air trapped in supply branch feed line Injector failure Replace line Flush and clean bearing Tighten connections and or replace line See System does not build sufficient pressure above Bleed air from line Repair or replace injector Injector indicator pin does not move when system builds up pressure Injector failure Feed line blocked Bearing plugged Seal stiction stat...

Page 25: ...sed from pres sure relief valve System pressure set too high Decrease power supply pressure to pump Pump runs too fast Reservoir out of lubricant Lubricant cavitation Leak in system Fill reservoir Install a follower plate Repair leak Pump runs without building pres sure Leak in distribution system Faulty vent valve seat Repair leak Replace needle and seat Lubricant coming out of breather Reservoir...

Page 26: ...ined in this document reflect the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice This manual contains English MM 309015 Graco Headquarters Minneapolis International Offices Belgium Korea China Japan GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 2000 Graco Inc is registered to I S EN ISO 9001 www graco...