Graco 309015B Guide

DESIGN GUIDE
309015B
Important Safety Instructions.
Read all warnings and instructions in this manual.
Save these instructions.
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. . . . . . . . . . . . . . . . . . . . . . . . . .

2 309015
Description
Graco Automatic Lubrication System
Refer to Fig. 1. Graco’s single-line parallel automatic lubrication system offers positive displacement lubrication
measurement for multiple lubrication points. This system was designed for use on mobile mining equipment, spe-
cifically haul trucks. At the heart of this system is the Graco Fireball pump, the most durable pump in the industry.
The pump provides the lubricant pressure needed to activate the automatic lubrication 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 pump on at the required lubrication intervals.
This System Design Guide provides general system information to aid and assist the user in designing, installing
and operation of an automatic lubrication system to meet the lubrication requirements of the designated equipment.

3309015
Notes

4 309015
Description (cont.)
Low Reservoir
Level Switch
User must provide.
Pressure Switch
For System Control
Remote Alarm Device
(Light or Horn)
User must provide.
Controller
Capabilities
Pump Power Supply
(air or hydraulic;
air power is shown)
Fig. 1
A
KEY Fig. 1
APump power supply
BRegulator
CSolenoid valve
DPump module
EIgnition switch
FPower supply valve (bleed-type valve
is required in air systems)
GSupply line
HInjectors
JTimer controller
KBattery
LGauge
MBearings
NQuick disconnect air coupler
PFeed lines
RGround wire
SBranch lines
B C
D
G
H
J
E
F
K
L
M
N
P
R
S
9656A

5309015
Description (cont.)
Typical Installation
The installation shown in Fig. 2 is only a guide for selecting and installing system components. Contact your Graco
distributor for assistance in planning a system to suit your needs.
Fig. 2
Low Reservoir
Level Switch
(Level Indicator,
optional)
Pressure Switch
For System Control
Remote Alarm Device
(Light or Horn)
(User provided)
Controller
Capabilities
KEY Fig. 2y
AHigh pressure hydraulic lines
BHydraulic tank line
CLubricant output connection
DPump module
EIgnition switch*
F3–Way solenoid valve
GHigh-pressure lubricant supply lines*
HInjector banks*
JLubrication controller*
KFill port
LOverflow port
MBreather
NFlow control valve (FCV)
PReservoir
RGround wire (for non–mobile installation)*
SPressure reducing valve (PRV)
THydraulic tank line*
UVent valve
VVent line
WFollower plate (optional)
XHigh pressure hydraulic line*
YHigh pressure hydraulic connection
ZTank hydraulic connection
AA Ball valve*
AB Level Indicator (optional)
* User provided
D
G
H
J
E
K
L
M
P
R
U
V
W
Front Back
A
G
BF
N
S
T
X
9649B
C
Y
Z
AA
Hydraulic
Reservoir
Return
From Hydraulic
Power Supply
AB

6 309015
Product Warnings and Cautions
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
This equipment is for professional use only.
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are uncertain about usage, 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 manuals. Read the fluid and solvent manufacturer’s warnings.
Handle hoses carefully. Do not use hoses to pull equipment.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82C (180F) or below –40C (–40F).
Do not lift pressurized equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.
Be sure breather is not plugged before filling reservoir.

7309015
Product Warnings and Cautions (cont.)
WARNING
SKIN INJECTION HAZARD
Fluid from the dispensing valve, leaks or ruptured components can inject fluid into your body and
cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on
the skin can also cause serious injury.
Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate
surgical treatment.
Do not put your hand or fingers over the end of grease outlet.
Do not stop or deflect leaks with your hand, body, glove or rag.
Follow the Pressure Relief Procedure in your separate pump manual if the injector 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 FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.

8 309015
Product Warnings and Cautions (cont.)
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
Ground the equipment and the object being dispensed to. See Grounding in your separate pump
manual.
If there is any static sparking or you feel an electric shock while using this equipment, stop dis-
pensing immediately. Do not use the equipment until you identify 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 removed.
Do not insert fingers in overflow port when filling reservoir.
Keep clear of all moving parts when you start or operate the pump.
Before you service this equipment, follow the Pressure Relief Procedure in your separate pump
manual to prevent the equipment from starting unexpectedly.

9309015
Automatic Lubrication Definitions
Definitions
“Pump on” time
The duration that the pump has power supplied to it. This is controlled by the timer. All injectors must fully dis-
pense within this time frame in a properly designed system.
“Pause interval” time
The duration between automatic lubrication cycles. This is also controlled by the timer. All injectors must fully vent
within this time frame in a properly designed 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 branch supply line prevents
system venting problems in cold weather by minimizing the amount of grease vented through the injector manifolds.
Feed line
The line that supplies lubricant from the injectors to the bearings.

10 309015
System Components
1. Controls
Timer
8852A
The timer is the “brain” of the automatic lube system. It requires a constant 24 volt power supply. Its function is to
supply and remove power from the pump module via a solenoid valve, at predetermined time intervals. The timer
must be programmed for “pump on” and “pause interval” settings.
Solenoid valve
9008A
The solenoid valve is controlled by the timer. The function of the solenoid valve is to turn the power supply on for
the 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 line pressure will
turn the pump module off upon detection of a preset pressure, normally 2500 psi (172 bar, 17 MPa). Two advan-
tages of a pressure switch are:
It can monitor system for faults.
It can turn the power supply to the pump off when a preset pressure has been reached.