Graco Single Line Parallel Lubrication System User's Manual
Contents
1. Ar RZ STANDARD 12 1 FLAPPER VALVE 7 PISTON 2 SCREEN 8 SPRING 3 BALL 9 LUBE CHAMBER 4 CHECK VALVE 10 DIAPHRAGM 5 LUBE OUTLET PORT 11 SEAL 6 AIR INLET OUTLET PORT 12 AIR CHAMBER CAVITY HIGH PRESSURE Figure 3 Air Operated Pump Operation SPECIFICATION mp _ Air Inlet Pressure Type Single pole double throw Stadard 40 to 150 psi 3 to 10 bar Oid Reservoir Only 10 Watt High Pressure 40 to 100 psi 3 to 7 bar 115 VAC 10 Watt Lube Outlet Pressure Single pole single throw reed Standard 9 1 360 to 1350 psi 25 to 93 bar Type ma a a High Pressure 24 1 960 to 2400 psi 66 to 165 bar Solid State Timer 3 Standard 1 5 cu in 24 59 cm Temperature range Operating O F to 131 F 18 C to 55 C High Pressure 1 4 cu in 22 95 cm Storage 67 F to 185 F 55 c to 85 C Lube Outlet Port 1 4 18 NPSF Component Technology Solid State CMOS Operating Temperatures w NLGI 1 40 F to 135 F 4 C to 50 C Cycle Frequency Adjustable Lubricant Oil or Grease NLGI 1 or lighter Range 1 1 2 min to 30 mins Air actuated positive Range 2 1 2 hour to 32 hours Type displacement On Time 0 2 min to 13 mins Standard LED Indicator Manual Run 50 50 H Grease or Oil Reservoir 15 amp Buttom Vibrations g S 99 Hz Switch 115 VAC Page 6 DIMENSIONS L12100 Figure 4 presents layouts of the standard and high pressure pumps along with common options NOTE DIME2. L12100 PUMP ORDERING INFORMATION xxx x VOLTAGE OPTION V1 12 VDC W TIMER V5 12 VDC W O TIMER V2 24 VDC W TIMER V6 24 VDC W O TIMER V3 115 VAC W TIMER V7 115 VAC W O V4 230 W TIMER SERVICE OPTION 05 OIL SERVICE GS GREASE SERVICE RESERVOIR OPTION 6 PINT PLASTIC OIL LIQUID GREASE R04 12 PINT PLASTIC OIL LIQUID GREASE R05 20 PINT PLASTIC OIL LIQUID GREASE LOW LEVEL OPTION LL LOW LEVEL SWITCH 10 WATT FOR OIL SERVICE ONLY OMIT IF NOT REQUIRED REPLACEMENT PARTS ORDERING INFORMATION Pump Assembly w Timer no reservoir 12 VDC Oil Pump Assembly w Timer no reservoir Ant 12 VDC Grease Pump Assembly w Timer no reservoir 24 VDC 01 Pump Assembly w Timer no reservoir m 24 VDC Grease 963588 550 001 6955 Pump Assembly w Timer no reservoir 115 VAC Oil Gee w Timer no reservoir CF w Timer no reservoir C anis w Timer no reservoir Y MM m vit M Pump Assembly w out Timer no reservoir 24 VDC Grease Pump Assembly w out Timer no P reservoir 115 VAC Oil 964426 990 001 831 Pump Assembly w out Timer no reservoir 115 VAC Grease Reservoir Assembles 20 pt Pasic 550 050 000 Consult Factory Consult Factory ephcementTansrmerzwo 492 210 008 20ft Cable w Mating Connector 12 24 VDC w 563142 492 240 244 Timer 4 Condictor 20ft Cable w Mating Conne
3. Page 5 L12100 OPERATION Figure 3 portrays the air operated pumps in the at rest position The figure represents both standard and high pressure pumps The description of operation applies to both At this point air is not present and spring 8 pressure has moved piston 7 to the down position When the piston is down flapper valve 1 opens and lubricant from reservoir fills lube chamber 9 above the piston Spring pressure on check valve 4 prevents lubricant from flowing through the outlet port This condition also allows residual pressure in the lube lines to raise ball 3 pass through screen 2 and return to the reservoir This venting of the output lines allows injectors to prime themselves When air at 40 to 100 psi 3 to 7 bar is applied to air inlet port 6 pressurized air fills air chamber cavity 12 forcing piston 7 upward pressurizing lubricant in lube chamber 9 The pressurized lubricant closes flapper valve 1 preventing the discharge lubricant from being fed back to the reservoir and forces check valve 4 open allowing lubricant to flow through lube outlet port 5 to the injectors When air pressure is removed spring 8 returns piston 7 to the down position to repeat the cycle On the standard pump a diaphragm 10 is used to seal the air chamber cavity 12 on the high pressure pump this is accomplished by a lip seal 11 OPTIONS Low Level Switches Several assemblies are available to
4. 12 Ib 5 44 kg w 3000 psi gauge 564422 550 000 470 20 Ib 9 06 kg w 3000 psi gauge 564423 550 000 480 COMPONENT ORDERING INFORMATION LUBRISYSTEM HAND OPERATED PUMP COMPONENTS Description PartNo Old Part No Pump Assembly 563580 550 000 520 3000 psi Gauge 557864 543 362 000 Reservoirs Plastic used for oil 6 pint 2 84 liter 562904 185 100 750 12 pint 5 68 liter 562889 185 100 060 20 pint 9 46 liter 562890 185 100 070 Plastic used for grease 6 Ib 2 72 kg 562905 185 100 760 12 Ib 5 44 kg 562884 185 100 000 20 Ib 9 06 kg 562885 185 100 010 See page 25 for fill studs and couplers Nominal grease reservoir size is based on a direct conversion of oil reservoir capacity and does not reflect volume loss due to the follower and spring Actual volumes contained are 6 Ib 2 6 Ib 12 Ib 5 8 Ib 20 Ib 11 8 Ib Page 12 ELECTRIC MOTOR PUMPS DESCRIPTION The electric motor LubriSystem pump Figure 8 is a rugged reliable pump for applications using oil or fluid grease as the lubricant The motor itself is a high torque gear reduction motor operating at 300 rpm and 115 VAC 50 60 Hz Other voltages are available The motor drives a positive displacement self priming gear pump capable of pumping at a rate of 2 0 cubic inches 32 8 cm per minute at 1 000 psi 69 bar All electric motor pumps are equipped with a Hirshman Connector A 20 foot mating cable is available as an accessory see ordering informat
5. moving the poppet 5 to the right sealing off the retainer 6 opening to the tank As the pump continues to run pressure exceeds the check valve 7 resistance The check valve opens allowing lubricant to flow through internal porting to the lube outlet and injector distribution system After 1250 psi 86 bar is obtained the relief valve 8 vents excess flow back to the tank maintaining constant pressure When the motor is de energized pressure relieves through the orifice 9 and the check valve closes The accumulator effect of the system now pushes on the poppet until the force exceeds the relieving force in passage 4 At this time the poppet moves to the left allowing lubricant pressure to vent to the tank through an opening in the retainer passage This allows the injectors in the system to reset and prepare for the next cycle i Sp f ACHT T n mf a an um d O r Ld MOTOR 6 RETAINER GEAR PUMP 7 CHECK VALVE INLET 8 RELIEF VALVE PASSAGE 9 ORIFICE POPPET Figure 9 Electric Motor Pump Operation L12100 OPTIONS DIMENSIONS Solid State Timer Figure 10 provides dimensions for the electric motor pump If the pump is equipped with the optional solid state timer The time and cycle time are controlled via screwdriver adjustable pots A manual run button is integral with the pump to be used for system check and syst
6. optional pressure switch or gauge may be added at the pump outlet port if required LubriSystem is referred to as a single line parallel system This means that when the solid state timer controller or operator activates the pump llubricant is forced down a single main line to manifolds and from there through parallel lines from individual injectors to the lube points If bearing point injectors are used no manifolds are required Instead the single main line branches into parallel lines feeding the bearing point injectors In both cases the injectores inject lubricant to a bearing shown in Figure 1 Once lubricant is dispensed at the lube points system pressure is vented by the pump This allows the injectors to prime themselves in preparation for the next lubrication cycle SYSTEM COMPONENTS Pumps Positive displacement air operated pumps are available in two 2 pressure ratios A manually operated pump and an electric motor pump are also offered Several different types and sizes Page 1 L12100 of reservoirs allow a system to be designed precisely for your application Reservoirs include a fill stud fp reservoir refilling Timer Solid state timer can be set to control the solenoid or motor to initiate lube cycle at intervals of 1 2 minute to 32 hours Manifolds and Injectors One manifold can distribute lubricant to as many as eight 8 injectors Injectors come in six 6 sizes to meet a range of lube requirements
7. 0 969 24 61 1 8 27 NPSF 1 156 29 36 1 8 27 NPTF Figure 14 Injector and Indicator Dimensions Injectors can be identified by the following characteristics Mo of Washers in Turned Hex vp EM m Bod m 0 002 MEE UM M 0 005 4 Jj yes j 0 08 HIGH OUTPUT 4 INJECTOR BODY sare 0 RING 0 RING METER VALVE bw CUP OUTPUT MA END 2009 09 999 I 1 2 24 THD INLE 8 HEX OUTPUT 5 8 HEX HEAD SPACER WASHER Page 20 L12100 DOUBLE SIDED SINGLE SIDED 0 875 22 23 AOO 0 875 p gt 1375 9 53 0 812 0 375 9 53 _ 0 375 9 53 266 DIA MTG HOLES 6 76 TYPICAL SIDE VIEW 1 4 18 NPSF SUPPLY PORTS 0 664 16 87 UTC YA X YER LAL a a La at at a bl eT 1 000 25 4 1 000 25 4 1 2 24 TYP DOUBLE SIDED DIMENSION SINGLE SIDED DIMENSION sow com _ sow com _ 0 906 3 500 4 250 0 906 3 500 4 250 23 01 88 90 108 0 23 01 88 90 108 0 Part No 561122 550 401 783 Part 0 561120 550 401 774 Figure 15 Extruded Aluminum Manifold Dimensions and Configurations Page 21 L12100 1 4 20 X 1 1 2 1 2 HEX HEAD SCREW 0 812 2 SUPPLIED EL 0 75 rcc 9 ae 174 18 NPSF BOTH ENDS STAINLESS STEEL NO OFPORTS s m i PARTNO OLD PARTNO 0 625 1 25 1 75 oss 125 DUST us
8. Bearing point injectors are fed directly from the pump through parallel branch lines and require no manifold Tubing Hardware Fittings and Accessories LubriSystem utilezes tough 3 16 in and 5 16 in heavywall nylon tubing and brass fittings for lube points Mounting hardware and accessories such as reservoir low level switches and injector indicator assemblies are available FEATURES AND BENEFITS A more efficient method of applying lubricant resulting in less machine downtime increased productivity and a safer work environment In addition to these benefits LubriSystem also provides e Stainless steel injectors and manifolds available for corrosive environments Easy system design and modification e inexpensive components and installation Fast payback In terms of savings in lube maintenance man hours alone LubriSystem usually pays for itself within the first year e Easy adjustability to meet a wide range of operating conditions e Quick connect fill stud on pump permits complete refill in minutes e High pressure pump can serve more points with longer tubing runs e Pump construction internally relieves system pressure requiring no extra cost in external valving e Several reservoir sizes available to fit a variety of applications e Visual indicator pin available fo system diagnostics HAND OPERATED PUMP SEE PAGES 9 THROUGH 12 y AIR OPERATED PUMP SEE PAGES 4 THROUGH 8 SOLENOID OPERATED AIR VALV
9. Watt Low Level Switch for oil plastic reservoir only 6 pint 2 84 liter size 12 pint 5 68 liter size 20 pint 9 46 liter size 15 Amp Low Level Switch for oil plastic reservoir only 6 pint 2 84 liter size 12 pint 5 68 liter size 20 pint 9 46 liter size 15 Amp Low Level Switch grease applications All Grease Reservoirs 063579 062892 062893 562907 562896 562897 563014 563015 563016 563318 563316 563317 563322 Standard Pump Repair Rebuild Kit includes Pump Diaphragm High Pressure Pump Repair Kit See page 25 for Fill Studs and Couplers 063762 550 000 280 550 000 790 185 100 820 185 100 380 185 100 390 185 100 780 185 100 540 185 100 550 456 010 171 456 010 172 456 010 173 521 001 050 521 001 030 521 001 040 521 001 110 521 001 020 521 002 100 550 200 040 163 400 000 550 050 240 461 301 030 550 400 792 550 402 500 Nominal grease reservoir size is based on a direct conversion of oil reservoir capacity and does not reflect volume loss due to the follower and spring Actual volumes contained are 6 Ib 2 6 Ib 12 Ib 5 8 Ib 20 Ib 11 8 Ib Page 8 L12100 HAND OPERATED PUMPS DESCRIPTION The multiple stroke positive displacement LubriSystem Hand Pump Figure 5 delivers 0 125 cubic inches 2 0 cm with each stroke of the handle The LubriSystem Hand Pump is available with standard clear plastic reservoirs for either oil or grease Modular pu
10. pressurized lubricant enters the injector inlet piston A shifts until the valve port is exposed Lubricant flows through the valve port and is directed behind piston B to chamber B1 This forces piston B towards the outlet dispensing a measured amount of lubricant from chamber B2 to the bearing When the pump has completed its dispense cycle it allows the pressure in the feed lines to vent This allows piston A to shift back towards the inlet opening the valve port to piston B Piston B shifts transferring the volume of lubricant in chamber B1 to chamber B2 This primes the injector in preparation for the next dispense cycle This operation is identical in both types of injectors PISTON B L12100 Note Although oil and grease injectors operate in the same manner each design has been optimized for use with its type of lubricant and system operating conditions Oil injectors are designed for lower viscosity lubricants higher cycle rates and lower operating pressure They will not function properly with grease Grease injectors are designed for grease consistency lubricants low cycle rates and higher operating pressure Their output accuracy will decrease with lighter lubricants and their life will be considerable reduced if used on high cycle rate systems PISTONA NR SY TX E m d lir k a aR Via x CHAMBER B1 CHAMBER B2 Figure 12 Injector Operation Page 18 INJE
11. 78 24 NPT Female s50 402 020 gt Stainless Steel Injectors Oil Bearing Point Injectors Oil Old Part No Old Part No Old Part No 550 100 120 550 100 130 550 100 490 550 100 500 L12100 ACCESSORIES HARDWARE Figure 17 Tubing unplasticized nylon Figure 18 Union Description Pato OldPartNo Description __________ PartNo Old Part no 5 16 in OD x 059 wall 7 9 x 1 5 black 60 ft 18 3 m 561132 550 450 230 Burst Pressure Min 1500 psi 103 bar at 75 F 24 C Point Distribution Line injector to lube point 3 16 in OD x 044 wall 4 8 x 1 1 black p 60 ft 18 3 m 561131 550 450 190 Burst Pressure Min 2000 psi 138 bar at 75 F 24 C Figure 19 Connectors SELF ALIGNING FERRULES AND NUTS Description PartNo Old Part No Description PartNo Old Part No Brass Nut w captive ferrule 3 16 tube 435 702 340 Brass Nut w captive ferrule 5 16 tube 435 702 503 Stainless Steel Nut 1 8 tube 556651 435 500 150 Male Connector 3 16 tube x 1 8 NPTF 556644 435 460 030 Stainless Steel Ferrule 1 8 tube 556654 435 510 050 Male Connector 5 16 tube x 1 8 NPTF 556645 435 460 060 Brass Inserts for 5 16 tubing pack of 20 55 963 550 402 330 Male Connector 5 16 tube x 1 4 NPTF 556646 435 460 070 Page 24 L12100 Figure 20 Tubing Straps Figure 22 Harness Clamps TUBING STRAPS HARNESS CLAMPS AND BRACKETS 1 2 12 7 diameter Figure 21 Elbows MISCELLANE
12. CTOR CYCLE INDICATOR OPERATION The injector cycle indicators are attached to the output side of aluminum injectors installed in an in line manifold only During the lube cycle they provide a visual indication that the injector has cycled Figure 13 represents an injector cycle indicator As the pump pressurizes the injector the injector piston moves toward the outlet pushing a measured amount of lubricant toward the lubrication point This piston contacts the plunger of the indicator moving it in the same direction As the plunger moves toward the indicator outlet the indicator stem is pushed toward the end of the indicator This opens the outlet of the indicator releasing the lubricant and extends the indicator stem past the indicator body This gives an indication that the injector has cycled When the pump has completed its cycle and the injector piston has retracted the spring loaded indicator stem retracts leaving the end of the stem flush with the indicator body and sealing the outlet port of the indicator The outlet of the injector cycle indicator accepts 1 8 inch tubing L12100 DIRECTION INJECTOR INDICATOR OUTLET 1 8 TUBE INDICATOR STEM PLUNGER DIRECTION OF C PISTON MOVEMENT INDICATOR INJECTOR SHOWN EXTENDED PISTON Figure 13 Injector Cycle Indicator Part No 563769 550 401 261 SPECIFICATION Operating Pressure max 2500 psi 173 bar Injectors 2500 psi 173 bar Min Pressur
13. Draw 0 2 amps 5 75 146 DIA Duty Cycle 30 run time not to exceed 2 min 230 VAC w timer Applied Voltage 230 10 50 60 Hz Current Draw 0 1 amps RESERVOIR SIZE C DIMENSION 6 PINT 2 84 LITERS 16 28 413 5 12 PINT 5 68 LITERS 20 78 527 8 20 PINT 9 46 LITERS 27 78 705 6 Duty Cycle 30 run time not to exceed 2 min Figure 10 Electric Motor Pump Dimensions Off Time Range 10 45 min Page 14 WIRING DIAGRAMS FOR ELECTRIC PUMPS HIRSCHMANN CONNECT OR BLACK BATTER Y _o WHITE BATTERY WHITE BATTERY RED IGNITION o 4X a PED IONITIO GREEN GROUND GROUND TO 8 32 SCREW ON MOUNTIN G BRACKET FUSE BOTH BATTER Y WHITE AND IGNITIO N RED 12 VDC 10A 24 VDC 5A For 12 amp 24 VDC with Timer HIRSCHMANN CONNECT OR BLACK WHITE N GREEN GROUND o GROUND TO 8 32 SCREW ON MOUNTIN G BRACKET FUSE BATTER WHITE 12 VDC 10A 24 VDC 5A For 12 amp 24 VDC without Timer Page 15 L12100 WHITE HIRSCHMANN _ CONNECT OR LACK GREEN GROUND TO 8 32 SCREW 7 ON TRANSFORME R USE TIME DELAY FUSE 115 VAC 0 25A 230 0 125A For 115 amp 230 VAC with Timer WHITE HIRSCHMANN 115 VAG CONNECTOR BLACK GREEN F GROUND TO 8 32 SCREW ON TRANSFORMER USE TIME DELAY FUSE 115 VAC 0 25A For 115 VAC without Timer
14. E ELECTRIC MOTOR PUMP SEE PAGES 13 THROUGH 160 dogo Figure 1 LubriSystem Diagram EX VE L12100 dX BEARING INJECTOR MANIFOLD BEARING POINT INJECTOR Page 2 L12100 SYSTEM OPERATION As shown in Figure 1 when the electic motor or solenoid operated air valve receives a signal from the timer or when the operator actuates the handle the pump is activated The pump dispenses lubricant either into the mainline tubing which distributes the lubricant to the manifolds feeding each injector or to lines supplying bearing point injectors Each of the injectors is sized to measure and dispense the proper amount of lubricant based on the size of the bearing Details of the operation of each component are included in this brochure INTERCHANGEABLILITY LubriSystem components are functionally interchangeable with other commonly used single line parallel injector systems Air inlet and lube outlet ports are 1 4 8 NPT typical of most other pumps in the field Injectors have a 3 16 in tube connection as standard An accossory indicator adaptor allows 1 8 in tubing to be connected to the outlet Mounting dimensions of Lubrisystem components are very close to theose of other systems And if some components there is a direct interchangeability in form and fit as well as function APPLICATIONS Typical applications of LubriSystem include the following e Mobile Equipment e Packaging Equipment Front End Load
15. NSIONS SHOWN ARE IN INCHES MILLIMETERS STANDARD 9 1 PUMP 6 87 DIA 175 50 63 129 6 2 ADIMENSION 12 72 323 17 22 437 HIGH PRESSURE 24 1 PUMP ALL DIMENSIONS ARE IDENTICAL TO 9 1 PUMPS EXCEPT THOSE SHOWN 9 38 137 OPTIONS 2 85 72 9 1 2 14 NPSM COND CONN 3 75 96 3 15 AMP GREASE LOW LEVEL 3 03 76 9 1 2 14 NPSM COND CONN 3 69 93 7 15 AMP OIL LOW LEVEL 1 2 14 NPSF COND CONN a 10 WATT OIL LOW LEVEL 1 50 1 L 3 Fp 219 1 2 COND 76 2 55 6 MANUAL OVER 0 875 HEX 22 23 1 4 NPSF SOLENOID VALVE Figure 4 Air Operated Pumps Dimensions Page 7 L12100 SYSTEM ORDERING INFORMATION LUBRISYSTEM AIR OPERATED PUMPS Descrntin PartNo oa Part no COMPONENT ORDERING INFORMATION LUBRISYSTEM AIR OPERATED PUMPS COMPONENTS Description PartNo Old Part No Standard Oil 6 pint 2 84 liter plastic reservoir 12 pint 5 68 liter plastic reservoir 20 pint 9 46 liter plastic reservoir 6 pint 2 84 liter plastic reservoir w 10 watt low level switch 12 pint 5 68 liter plastic resevoir w 10 watt low level switch 20 pint 9 46 liter plastic reservoir w 10 watt low level switch Standard Grease 6 Ib 2 72 kg plastic reservoir 12 Ib 5 44 kg plastic reservoir 20 Ib 9 06 kg plastic reservoir 6 Ib 2 72 kg plastic reservoir w low level switch 12 Ib 5 44 kg plasti
16. OUS ELBOWS Description PartNo Old Part No Description PartNo Old Part No Steel Pipe and Adaptor Elbows 1 4 28 male x 1 8 NPTF female 90 Pressure Gauge Kit 3000 psi for Air Pump 560 001 780 Adapter Elbow LEE Fill Studs Pneumatic Oil Pumps 563155 506 189 010 90 Street Elbow 1 8 NPTF 15 783 509 110 000 Pneumatic amp Hand Grease Pumps 557374 506 189 001 45 Street Elbow 1 8 NPTF 557395 509 111 000 Electric Oil amp Fluid Grease Pumps 557880 550 050 300 Brass Male Tube Elbows Fill Couplers mate w above fill studs 3 16 tube x 1 8 NPTF 556638 435 440 030 Pneumatic Oil Pump 558906 506 322 000 5 16 tube x 1 8 NPTF 556639 435 440 060 Pneumatic amp Hand Grease Pumps 558906 506 322 000 5 16 tube x 1 4 NPTF 556640 435 440 070 Electric Oil amp Fluid Grease Pumps 557877 550 050 230 Page 25 HOW TO ORDER LUBRISYSTEM ANALZING SYSTEM REQUIREMENTS 1 Determine individual bearing requirements Graco literature No L20115 provides a procedure for calculating the lubricant volume requirement for individual lube points 2 Analyze bearing locatoins and group those that can conveniently fed from a single manifold See ordering instructions 3 Analyze routine maintenance setup to determine reservoir options and other accessories required ORDERING INSTRUCTIONS 4 Selectthe quantity of each injector size required 5 Specify the manifolds required based on the groupings of injectors 6
17. Order a Timer or Controller 7 Select pump reservoir configuration and specify part number using one of the following e Grease Reservoir specify appropriate assembly number e il Reservoir specify appropriate assembly number 8 Order Part No 553315 521 001 020 115 VAC or 553332 521 002 100 24 VDC solenoid valve Install in pump air inlet port 9 Specify appropriate pressure switch in one is required using Bulletin No L15521 Part No 557828 542 210 107 is usually used 10 Specify Part No 557559 514 215 001 if a pressure gauge is required 0 3000 psir See Bulletin No L15326 11 Select fittings accessories and mounting harware to complete installation Required only for air operated pumps FOR MORE INFORMATION Literature No L20102 LubriSystem Design Guide Guidelines and information for LubriSystem component selection and design calculation charts Literature No L14521 Solid State Timer Literature No L14530 TC 1000 Timer Counter Literature No L14540 LC 1000 Controller T Literature No L14750 WMP Maxi Monitor T Literature No L14760 Multi Purpose Controller T Literature No L15521 Pressure Switch Literature No L20115 Procedure for calculating the lubricant volume requirement for various types of rotating and moving lubrication points T Requires a system mounted pressure switch All written and visual data contained in this document are based the latest produ
18. TIONS To check that a system is not oversized for a pump the following calculations need to be performed 1 Sum the output volume of all injectors used in the system 2 Add the number of injectors used in the system and multiply by 004 cu in This is total volume required to re prime the injector 3 Total system requirement is the sum of 1 and 2 and should be less than 50 of the total output per cycle for the pump selected The 50 is a rule of thumb to allow for line expansion and fluid compressibility If totals are more than 50 of pump output the following steps can be taken 1 Select smaller injectors and increase system cycle frequency 2 Split the system up and use 2 or possibly more pumps L12100 Page 4 All reservoirs used with grease are equipped with a spring loaded follower which provides a positive air free supply of grease to the pump Pumps are equipped with a fill stud and strainer to allow easy filling of the reservoir from a supply source Oil reservoirs are also equipped with a fill cup and strainer allowing easy refilling from an oil can Optional low level switches timers and solenoid operated air valves are available to custom design your application The solenoid operated air valve designed for use with air operated pumps is controlled by a solid state timer or other electronic controller The solenoid is a 115 VAC three way normally closed valve with a manual override The manual ov
19. ator is pressurized the stem of the indicator extends When the indicator is not pressurized the indicator stem is not visible These indicators give an immediate visual indication that the injector has cycled Injector cycle indicators are not available for stainless steel or bearing point injectors Manifolds are available in two types of materials aluminum and stainless steel The number and configuration of outlet ports can also be ordered to meet the specific needs of the system Refer to pages 21 22 and 23 for more specific information on dimensions and configurations of manifolds Aluminum manifolds are available with 4 outlet ports in an in line single sided configuration They are also available with 8 outlet ports in an in line double sided configuration These manifolds are dimensionally interchangeable with many of those used on other single line parallel injector systems Stainless steel manifolds are available with 1 2 3 or 4 outlet ports in an in line configuration These also interchange with others in common use Plugs are available to close off any port not required A torque of only 1 to 2 ft lbs is required to provide a leak tight connection between the injectors and manifold INJECTOR OPERATION Lubricant from the pump is supplied either to the manifold which in turn provides lubricant to the manifold injectors or directly to the bearing point injector Figure 12 represents a typical manifold injector When
20. c reservoir w low level switch 20 Ib 9 06 kg plastic reservoir w low level switch High Pressure Oil 6 pint 2 84 liter plastic reservoir 12 pint 5 68 liter plastic reservoir 20 pint 9 46 liter plastic reservoir 6 pint 2 84 liter plastic reservoir w 10 watt low level switch 12 pint 5 68 liter plastic resevoir w 10 watt low level switch 20 pint 9 46 liter plastic reservoir w 10 watt low level switch High Pressure Grease 6 Ib 2 72 kg plastic reservoir 12 Ib 5 44 kg plastic reservoir 20 Ib 9 06 kg plastic reservoir 6 Ib 2 72 kg plastic reservoir w low level switch 12 Ib 5 44 kg plastic reservoir w low level switch 20 Ib 9 06 kg plastic reservoir w low level switch 063574 063575 063576 563577 563578 563571 563572 563573 550 000 170 550 000 180 550 000 190 550 000 230 550 000 240 550 000 250 950 000 050 950 000 060 550 000 070 950 000 080 950 000 090 550 000 100 550 000 940 950 000 950 950 000 960 550 001 000 550 001 010 550 001 020 550 000 820 950 000 830 550 000 840 950 000 850 950 000 860 550 000 870 Standard Pump no reservoir High Pressure Pump no reservoir Plastic Reservoirs for oil only standard or high pressure 6 pint 2 84 liter 12 pint 5 68 liter 20 pint 9 46 liter Plastic Reservoir for grease standard or high pressure 6 Ib 2 72 kg 12 Ib 5 44 kg 20 Ib 9 06 kg 10
21. ct information available at the time of publication Graco reserves the right to make changes at any time without notice Contact us today To receive product information or talk with a Graco representative call 800 533 9655 or visit us online at www graco com 2012 Graco Inc Form No L12100 Rev C 8 12 Printed in U S A All other brand names or marks are used for identification purposes and are trademarks of their respective owners All written and visual data contained in this document are based on the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice
22. ctor 12 24 VDC S w o Timer 115 230 VAC all 3 Conductor Consult Factory Consult Factoru Consult Factory Page 16 INJECTORS AND MANIFOLDS DESCRIPTION Oil injectors in two types and grease injectors in one type Figure 11 are available for use in the lubrication system The first a manifold injector is designed specifically for mounting in the LubriSystem manifold The second a bearing point injector is designed to be mounted at the lubrication point and does not require a manifold Manifold injectors are available for oil or grease and are positive displacement spring loaded devices used in the LubriSystem manifold These injectors are available in six displacements from 0 0015 to 0 024 cu in 0 025 to 0 039 cm of lubricant per injector cycle The choice of displacements fits a wide range of applications Input to the injector is from the manifold Output is into lines delivering the lubricant to a specific lube point Injectors are available in either an aluminum alloy or stainless steel The inlet port of all injectors utilizes a 1 2 24 in tubing An indicator adaptor is available to change 3 16 in tube connection to 1 8 in for use with 1 8 in tubing Stainless steel injectors come standard with 1 8 in fittings Bearing point injectors are positive displacement spring loaded devices that can be mounted directly at the lubrication point Figure 11 Injectors and Manifolds Bearing point injector
23. e ooo 0 594 2 0 2 5 zo 25 0 563 2 75 3 25 14 3 69 8 82 6 063766 550 401 103 0 532 35 4 0 13 5 88 9 1016 227 07 590 401 104 Figure 16 Stainless Steel Manifold Dimensions and Configurations Page 22 ORDERING INFORMATION LUBRISYSTEM MANIFOLD AND ACCESSORIES Description ___________ Old PartNo Manifolds Stainless Steel 1 Port Manifold 2 Port Manifold 3 Port Manifold 4 Port Manifold Manifolds Aluminum 4 Port Manifold 8 Port Manifold Double Sided Manifold Accessories 563764 563765 563766 563767 550 401 101 550 401 102 550 401 103 550 401 104 561120 561122 550 401 774 550 401 783 Manifold Injector Port Plugs 15M038 561115 550 350 040 550 401 120 Aluminum Manifold Stainless Steel Manifold End of Line Manifold Plugs Aluminum Manifold 555808 006425 550 050 210 Stainless Steel Manifold 412 700 394 Spacers Old Part No ET Adjustment Aluminum Alloy Injectors Oil 002 0 033 1 005 L3 ee e sse ses 6900030 se seo eas __4 sese sooo s6605 550100040 s sso 5010080 ser Page 23 Aluminum Alloy Injectors Grease oosa 5 see 6010000 553m L12100 INJECTOR ACCESSORIES Description Od Part Adaptor
24. e to Fire Injectors 450 psi 31 bar 160 psi max 11 bar Min On Time 30 sec Min Off Time 3 min Torque Specs Operating Pressure max Vent Pressure Installing Injector into 2 3 ft Ibs Manifold Tightening Tube Nut 18 36 in lbs Page 19 DIMENSIONS Injectors All manifold injectors are approximately 2 125 inches 54 mm long with a 0 625 inch 15 88 mm hex body For injectors utilizing from one to four output adjustment spacers add 0 04 inch 1 mm per spacer to the length All bearing point injectors are approximately 2 5 inches 63 5 mm long with a 0 625 15 88 mm hex body For injectors utilizing from one to four output adjustment spacers add 0 04 inch 1 mm per spacer to the length Figure 14 provides dimensions for the two types of injectors Manifolds Figures 15 and 16 provide dimensions for aluminum and stainless steel manifolds L12100 ALUMINUM MANIFOLD INJECTOR STAINLESS STEEL MANIFOLD INJECTOR OIL OR GREASE 02 ac x Lip rasa FE PELLE mm d dl EL EROR EE E NSW I ANNE das 0 38 9 65 HE 0 38 9 65 HEX FOR 1 8 TUBE FOR 3 16 TUBE INJECTOR CYCLE INDICATOR BRASS BEARING POINT INJECTOR OIL FOR ALUMINUM INJECTOR PLATED CARBON 1 8 TUBE STAINLESS STEEL STEEL AERA ELLE SS mm prb 97 7 NS E Vs al 2 55 64 77
25. em filling purging When depressed it will activate the pump output as long as button is held in Pressing button will not reset timer The timer option fits neatly beneath the motor cover adding nothing to the overall dimensions of the pump package Low Level Switches Several assemblies are available to provide a signal when the reservoir oil level is low Low level switch assemblies depend on floats that fall with the depletion of lubricant and actuate contacts on the switch These switches are rated at 10 watts and are used to activate a warning device such as a light or alarm The 10 watt assemblies are used to provide input to controllers which may be programmed to use the input signal as desired SPECIFICATION Pump Output 2 0 in 33cm per min Lube Output Port 1 4 18 NPSF Oil all temperatures NLGI 00 grease for 50 F or higher NLGI 000 grease for below 50 F Type Electric motor driven postive displacement self priming Low Level Switches 10 watt switch Rating at 115 s Type Single pole single throw reed type switch normally closed Electical Specifications 12 VDC w w o timer Applied Voltage 12 VDC Current Draw 5 amps 0 343 DIA Lubricant 8 71 MOUNTING HOLES Duty Cycle 30 run time not to exceed 2 min 24 VDC w w o timer Applied Voltage 24 VDC Current Draw 5 amps Duty Cycle 30 run time not to exceed 2 min 115 VAC w w o timer Appllied Voltage 115 1096 50 60 Hz Current
26. erride simplifies system testing line filling and line bleeding by allowing the operator to control when the pump dispenses lubricant When the solenoid receives a 115 VAC signal from its controller it actuates the valve to allow air flow to the pump While the solenoid is energized the pump strokes forward sending lubricant through the system When the solenoid is de energized the pump piston returns An FR unit FRL with high pressure pumps must be used upstream of the air valve to remove harmful dirt and water from the air supply Air pressure should be a maximum of 100 psi 7 bar for the high pressure pump or 150 psi 10 bar for standard pumps MOUNTING sturdy bracket with four mounting holes holds pump with solenoid and reservoir Assembly should be mounted in a protected centralized and readily accessible location Pump must be mounted in a vertical position only with reservoir up Use four 5 16 inch or M8 machine screws at the mounting holes to ensure secure placement FEATURES BENEFITS Proven dependable performance Many pumps now in use have logged over 5 years of trouble free operation Pump features include e Simple design few moving parts results in less wear and downtime e Compact modular construction allows you to customize the pump reservoir design to fit your application e Lube supply status at a glance e Rugged aluminum construction to provide lightweight features with heavy duty capabilities
27. ers Palletizers Haul Trucks Stackers Blast Hole Drill Rigs Wrappers Paving Equipment e Lumber Equipment e Plastic Rubber Industrial Equipments Debarkers Tire Presses Edgers Injection Molders REUKE Planers e Food Processing Equipment Jonas Grates Peelers Saw Guides Washers Winders Mixers Presses Ovens Conveyors Can making Machines Page 3 AIR OPERATED PUMPS DESCRIPTION LubriSystem air operated pumps Figure 2 are available in two Traber lube to air power ratios to meet your system requirements The LubriSystem standard pump has a 9 1 ratio while the high pressure pump provides a 24 1 ratio Output per stroke is 1 5 cubic inches 24 59 cm for standard pumps and 1 4 cubic inches 22 95 cm for high pressure pumps Both pump bodies are made from strong lightweight aluminum and are furnished with a corrosion resistant coating This coating provides a tough durable impact resistant finish which is exceptionally resistant to corrosion excellent for salt spray or humid environments Pump piston and cylinder bore are precision machined and finished to minimize wear and discourage corrosion Reservoirs in several different sizes are available in transparent plastic All reservoirs mount directly to the pump and are easily interchangeable The level of lubricant in the reservoir is easily checked due to the transparent plastic Figure 2 Air Operated Pump SYSTEM SIZING AND CALCULA
28. ion on page 16 No motor starter or capacitor is required Pumps may be ordered with an integral solid state timer or control may be provided by an external system controller Reservoirs in several different sizes are available in transparent plastic All reservoirs mount directly to the pump and are easily interchangeable The level of oil in the reservoir is easily checked due to the transparent plastic Pumps are equipped with a fill stud and filter screen to allow easy filling of the reservoir from a supply source Optional low level switches and timers are available to custom design your application MOUNTING sturdy bracket with four mounting holes holds pump with motor timer and reservoir The assembled components should be mounted in a protected centralized and readily accessible location Pump must be mounted in a vertical position only with reservoir up Use four 5 16 inch or M8 machine screws at the mounting holes to ensure secure placement Figure 8 Electric Motor LubriSystem Pump Page 13 L12100 FEATURES BENEFITS PUMP FEATURES INCLUDE e Reliable gear pump design proven in mobile equipment applications e Energy efficient motor uses only 25 watts e Allows the design of an all electric system no air required OPERATION Figure 9 portrays the pump in the at rest position When the motor 1 is energized the gear pump 2 runs drawing in lubricant through inlet 3 Pressure builds in passage 4
29. mp reservoir design plus built in features readily tailor the LubriSystem Hand Pump to a wide range of applications The pump is sturdily built of aluminum and steel in a compact space saving package Even with an integrally mounted 20 pint or 20 pound capacity reservoir it stands only 25 3 inches 644 mm high is 7 25 inches 184 mm wide and 11 03 inches 280 mm deep It requires only 24 3 inches 617 mm clearance from the mounting surface for a full handle pull MOUNTING Sturdy bracket with two mounting holes hold pump with reservoir The assembly components should be mounted in a protected centralized and readily accessible location Pump must be mounted in a vertical position only with reservoir up Use two 3 8 in or M10 machine screws at the mounting holes to ensure secure placement Figure 5 Hand Operated Pump Page 9 FEATURES BENEFITS e Interchangeable reservoirs make it easy to customize the pump package for each application e Simple positive displacement pump design keeps the number of wear parts to a minimum for extended pump life Built in bleed mechanism provides system pressure venting when the pump handle is returned to the fully upright position 3000 psi pressure gauge provides a fast check on system status OPERATION Figure 6 shows a cutaway view of a hand operated pump As the pump handle 1 is pulled down piston 2 moves forward past the detent 3 closing the relief to tank por
30. provide a signal when the lubricant level is low Low level switch assemblies used on oil reservoirs depend on floats that fall with the depletion of lubricant and actuate contacts on the switch Switch assemblies used on grease reservoirs are actuated when a cable attached to the grease follower is pulled away from the switch as the follower reaches the low position Limit switch assemblies used on grease reservoirs are rated at 15 amps Oil reservoirs use 10 watt reed type switches The low level assemblies with a 15 amp rating are often used to activate a warning device such as light or alarm The 10 watt assemblies are used to provide input to controllers which may be programmed to use the input signal as desired Solid State Timer This solid state timer can be used to initiate pump cycles on a time basis at intervals from 1 2 minute to 32 hours A built in memory retains the cycle time for 1 1 2 hours during power failure or machine shutdown to resume from the point where it was suspended For details see Literature No 14521 sophisticated multi function controllers are also available for use in systems using pressure switches Refer to literature No 14540 LC 1000 and 14750 WMP III L12100 RESERVOIR IN n 4 m iP L NINN NE x iN K NN VERE Lj oe VF NM PAN ecu S A VER dd 5 AN JE UL Er
31. s are available in five output capacities from 0 0015 to 0 012 cubic inches 0 025 to 0 2 cm of lubricant per injector cycle Input to the bearing point injector is from the pump using a parallel branch from the main line Bearing point injectors utilize a stainless steel body The inlet port of this type of injector is 1 8 27 NPSF The outlet port is a standard 1 8 27 NPTF male thread for attachment at the lubrication point Page 17 L12100 Both injector styles are designed with a unique feature allowing output capacity to be changed using adjustment spacers This reduces the number of replacement injectors to be stocked also permits increasing decreasing an injector s lube delivery capacity in order to deal with unexpected needs to change the amount of lubricant delivered to lube points after installation Positive displacement injectors dispense a precisely metered amount of oil or grease to a lube point with every lube cycle Injectors are inexpensive and disposable They should be replaced if not functioning properly If an injector is to be disassembled for purposes of adding or deleting output adjustment spacers great care must be taken to make sure both the inside and outside of the injectors are dirt free when reassembled in the system An injector cycle indicator is available for use in system diagnostics This cycle indicator can be attached to the output end of aluminum injectors When the pump cycles and the indic
32. single Line Parallel Lubrication System Multiple Point Lubrication Using Oil or Grease PROVEN QUALITY LEADING TECHNOLOGY LubriSystem Automated Centralized Lubrication System that can be used in virtually any application where centralized operation is desired e Dependable e Economical e Versatile e Adjustable injector outputs e Up to 100 or more lube points e Use with oil or grease e Wide range of options e Modular design e Option of aluminum or stainless steel injectors and manifolds INTRODUCTION LubriSystem M utilized one of three 3 types of pumps single stroke air operated pump a multiple stroke hand operated pumpr or a continuous flow electric motor pump Fed from a lubrican reservoir mounted above the pump output is delivered to oil or grease metering valves called meters or injectors which distribute lubricant to bearing points Oil or grease NLGI 1 or lighter may be used with the hand operated and air operated pump Oil or NLGI 00 or ligher grease may be used with the electic motor pump Air operated pumps require a solenoid operated air valve and controller to activate the pump Electic motor pumps use an electric motor 115 VAC is standard and a solid state timer device to activate the pump The injectors are mounted in manifolds supplied by Graco The bearing point injectors mount at the bearing point and require no manifold Various accessories are available to simplify installation An
33. t 4 Further forward motion of piston 2 displaces the volume of lubricant in cavity 8 through connecting port 5 and check valve 6 and to the outlet 7 The handle is then partially returned until the detent ball 3 contacts but does not retract into the ball indent cavity If the handle is returned too far the pressure built up in the lube cavity 8 will be vented indicated by a decrease in the pressure gauge s reading Continue to stroke the pump until the pressure gauge reads 1500 psi 103 bar for oil or 2500 psi 173 bar for grease After system pressure has been attained causing all the injectors to dispense lubricant the pump handle is returned to the full upright position past the detent This allows system pressure to vent through port 4 back to reservoir thereby allowing the injectors to reset and prime for their next delivery of lubricant PRESSURE GAUGES Pressure Gauges are installed in the pump outlet to allow the operator to know when correct pressure has been attained When correct pressure has been reached the operator returns the handle to the full upright position venting line pressure and allowing the injectors to reset L12100 HANDLE PISTON DETENT BALL RELIEF TO TANK PORT CONNECTING PORT CHECK VALVE OUTLET LUBE CAVITY DETENT CAVITY 0 GAUGE PORT VW i AA E ep rd bp oA 77 5 Figure 6 Hand Operated Pump Operation Full upright position sho
34. wn Force to Operate Handle 20 Ibs 9 kg per 1000 psi 69 bar Oil or Grease NLGI 1 or lighter Reservoir Capacities 6 pints 2 84 liters or 6 105 2 72 for oil or grease plastic 12 pints 5 68 liters or 12 Ibs 5 44 kg 20 pints 9 46 liters or 20 Ibs 9 06 Nominal grease reservoir size is based on a direct conversion of oil reservoir capacity and does not reflect volume loss due to the follower and spring Actual volumes containd are 6 Ib 2 6 Ib 12 Ib 5 8 Ib 20 Ib 11 8 Ib Page 10 L12100 DIMENSIONS Figure 7 provides dimensions for the hand operated pump DETENT POSITION PRESSURE RELIEF POSITION FULLY UP RIGHT FILL CUP OIL 17 03 FULL STROKE 433 RES V ONLY 3 91 cn 99 3 11 0 PUMPING 279 9 79 STROKE 19 05 FILL STUD GREASE RES V ONLY PUMPING 0 437 11 10 DIA MOUNTING HOLES TWO PLACES 1 4 NPT LUBE OUTLET 0 3000 PSI PRES SURE GAUGE RESERVOIR SIZE 6 20 ADIMENSION 10 5 267 15 381 22 559 Figure 7 Hand Operated Pump Dimensions Page 11 L12100 SYSTEM ORDERING INFORMATION LUBRISYSTEM HAND OPERATED PUMPS Hand Operated Pump w Plastic Reservoir for oil 6 pint 2 84 liter w 3000 psi gauge 550 000 430 12 pint 5 68 liter w 3000 psi gauge 564419 550 000 440 20 pint 9 46 liter w 3000 psi gauge 564420 550 000 450 Hand Operated Pump w Plastic Reservoir for grease 6 Ib 2 72 kg w 3000 psi gauge 564421 550 000 460
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