Graco Spindl-Gard SG-1 Operation manual

Spindl-Gard®SG-1/SG-2 System
Operation & Service Instructions

L42110
Spindl-Gard SG-1 and SG-2 Systems
TABLE OF CONTENTS
Section/Para Page
1 Introduction ..................................................................... 1-1
1.1 Purpose of Manual............................................................ 1-1
1.2 Spindl-Gard Overview ....................................................... 1-1
1.3 SG-1 Components and Operation Overview....................... 1-1
1.4 SG-2 Components and Operation Overview....................... 1-4
2 Installation Guidelines..................................................... 2-1
2.1 General............................................................................. 2-1
2.2 SG-1 System Installation................................................... 2-1
2.3 SG-2 System Installation................................................... 2-6
3 System Startup and Operation........................................ 3-1
3.1 General............................................................................. 3-1
3.2 System Filling and Bleeding.............................................. 3-1
3.3 Daily Start-Up ................................................................... 3-5
3.4 Operation.......................................................................... 3-6
3.5 Shutdown ......................................................................... 3-6
4 Troubleshooting............................................................... 4-1
4.1 General............................................................................. 4-1
4.2 Troubleshooting SG-1 Components ................................... 4-1
4.3 Troubleshooting SG-2 Components ................................... 4-2
5 Parts Ordering Information ............................................. 5-1
5.1 General............................................................................. 5-1
5.2 SG-1 Spray Nozzle............................................................ 5-2
5.3 Mixing Tee ........................................................................ 5-4
5.4 Nozzle Adapter.................................................................. 5-5
5.5 Easy to Replace Nozzle Adapter ........................................ 5-6
LIST OF ILLUSTRATIONS
Item Page
1-1 SG-1 System.................................................................... 1-2
1-2 SG-2 System.................................................................... 1-5
2-1 Spindl-Gard Installation .................................................... 2-2
2-2 Typical Spray Nozzle Installation....................................... 2-3
Item Page
2-3 SG-1 Typical Machining Head Modification ....................... 2-4
2-4 Reversing Seals................................................................ 2-4
2-5 Pump and Header Installation........................................... 2-5
2-6 Nozzle Tube Applications .................................................. 2-6
2-7 Nozzle Tube Installation .................................................... 2-7
2-8 Mixing Tee........................................................................ 2-8
2-9 Air Flow Switch Installation............................................... 2-9
2-10 Air Flow Switch and Mixing Tees................................... 2-10
3-1 Filling Secondary Divider Valves Supply Tubes .................. 3-3
3-2 Bleeding Secondary Divider Valves ................................... 3-3
3-3 Bleeding Pump-Supplied Master Divider Valve.................. 3-4
3-4 Bleeding Header-Supplied Master Divider Valve................ 3-4
3-5 Typical Indicator Pin and Cycle Switch.............................. 3-5
4-1 Spray Nozzle .................................................................... 4-3
4-2 Mixing Tee........................................................................ 4-3
5-1 Spray Nozzle Parts Identification....................................... 5-3
5-2 Missing Tee ...................................................................... 5-4
5-3 Nozzle Adapter ................................................................. 5-5
5-4 Easy to Replace Nozzle Adapter........................................ 5-6
LIST OF TABLES
4-1 System Troubleshooting ................................................... 4-2
5-1 Standard System Components ......................................... 5-1
5-2 SG-1 Components............................................................ 5-1
5-3 SG-2 Components............................................................ 5-1
5-4 Spray Nozzle (Figure 5-1) Parts List.................................. 5-3
5-5 Mixing Tee (Figure 5-2) Parts List ..................................... 5-4
5-6 Nozzle Adapter (Figure 5-3) Parts List............................... 5-5
5-7 Easy to Replace Nozzle Adapter (Figure 5-4) Parts List ..... 5-6

1-1
Spindl-Gard SG-1 and SG-2 Systems L42110
1.1 PURPOSE OF MANUAL
1.1.1 This manual is designed for users of Spindl-Gard
systems designated SG-1 (for multi-spindle heads)
and SG-2 (for precision spindles). Procedures and
instructions are provided for installation, start-up,
operation, troubleshooting and maintenance. Although
the components and assemblies used will vary
between different systems there are common rules and
procedures which apply to any installation.
1.1.2 The SG-1 and SG-2 systems use many similar com-
ponents and some procedures discussed in the manual
apply to both types of systems. If procedures differ
between the systems, the procedures are covered
separately to allow the user to quickly locate the specific
area of concern. A table of contents is provided at
the start of each section to allow for quick and easy
reference.
1.1.3 Refer to Bulletin L20110 for additional SG-1 and
SG-2 system and product specifications.
1.2 SPINDL-GARD OVERVIEW
Spindl-Gard was developed to lubricate single and multi-
spindle machining heads. A unique spray nozzle utilized
with other Spindl-Gard components provides precise
amounts of oil to a specific bearing surface. Oil is applied
at the proper frequency and in the right quantity to meet
the lubrication requirements, keeping bearings, gears,
shafts and seals running cool. Spindl-Gard provides full
protection without over-or under-lubing.
1.3 SG-1 COMPONENTS AND OPERATION
OVERVIEW
1.3.1 General. SG-1 utilizes a standard Trabon pump package
(typically, Graco’s Modu-Flo®series), a Model MSP
lubricant divider valve with cycle indicator switch, Maxi-
Monitor®controller, and various fluid line accessories.
(See Figure 1-1.) In some cases, the machine controller
will be used in lieu of the Maxi-Monitor controller. Each
shot of lubricant from the pump is distributed by the
divider valve to the appropriate lube point. Depending
upon machining head design, some bearings may
receive lubricant directly from the divider valve while
others, including gears, may receive lubricant from spray
nozzles located in the gear cavity. Pressure switches
may be used to monitor air pressure in the machining
head. By using the feedback features of the divider
valve, it is possible to monitor lubricant and pressure
delivery status to all points at all times. An SG-1 circuit is
shown in Figure 1-1.
1.3.2 SG-1 Components
1.3.2.1 General. Paragraphs 1.3.2.2 through 1.3.2.9 provide
a brief description of components used in typical SG-1
systems. See Section 5, parts ordering information, for
corresponding part numbers.
SECTION 1
INTRODUCTION
1.1.PURPOSE OF MANUAL ...................................................... 1-1
1.2. SPINDL-GARD OVERVIEW.............................................. 1-1
1.3.SG-1 COMPONENTS AND OPERATION OVERVIEW .............. 1-1
1.3.1 General ................................................................. 1-1
1.3.2 SG-1 Components................................................. 1-1
1.3.3 SG-1 Operation ..................................................... 1-3
1.4.SG-2 COMPONENTS AND OPERATION OVERVIEW .............. 1-4
1.4.1 General ................................................................. 1-4
1.4.2 SG-2 Components................................................. 1-4
1.4.3 SG-2 Operation ..................................................... 1-4
OPERATION AND
SERVICE INSTRUCTIONS

Spindl-Gard SG-1 and SG-2 Systems
1-2
L42110
Figure 1-1. SG-1 System

1-3
Spindl-Gard SG-1 and SG-2 Systems L42110
1.3.2.2 Controller. Several means of control are available for the
SG-1. Operation can be controlled by signals from user’s
machine control or by one of several controllers available
from Graco as follows:
WMP Maxi-Monitor• ®: This microprocessor-based
controller can be used to schedule and initiate lube
cycles on a machine cycle or time basis as well as
to relay fault conditions.
Solid-State Timer: This solid-state timer can be•
used to initiate lube cycles on a time basis. 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.
Flexi-Monitor: Utilizing the latest solid-state•
programmable control technology, the Flexi-Monitor
controls complex multiple-zone lubrication systems.
Not only does the Flexi-Monitor control lubrication
cycles, but it can monitor and report every aspect
of the lubrication system; including temperature,
vibration, fluid flow, pressure, and system operating
status.
1.3.2.3 Pump Package. Several types of pump packages
are available to supply oil to the Spindl-Gard system.
Most applications use a Modu-Flo series pump
package equipped with a reservoir sized to the system
requirements. This series of pumps may either be
pneumatic- or hydraulic-powered and is available
in different lube output capabilities to fit the specific
requirements of each system.
1.3.2.4 Filter. A 10-micron filter placed in the outlet line of the
pump provides filtration of oil entering the system. A final
ten-micron oil filter at the divider valve inlet provides the
final filtration before oil enters the divider valve.
1.3.2.5 Divider Valve. This valve meters the precise amount of
oil required for each Spindl-Gard nozzle or terminating
lube point. The divider valve consists of stackable
sections, each of which can provide oil to one or two lube
points. The sections can be arranged to provide metered
oil to up to sixteen lube points. A valve section can be
supplied with a cycle indicator pin to provide visual
indication that the divider valve is cycling. The indicator
pin can also be used to actuate a cycle switch which
then provides a signal to the system controller.
1.3.2.6 Cycle Switch. The cycle switch is a limit switch which
is actuated by the movement of the cycle indicator pin.
If a blockage occurs in a lube line, the divider valve will
not cycle and the cycle switch will not be actuated. If
the switch is not actuated within a set time period, the
controller provides a warning signal.
1.3.2.7 Proximity Switch. The proximity switch is a proximity-
type sensor which is attached to the valve section of the
divider valve and senses the movement of the divider
valve piston during cycling. The proximity switch provides
a signal that is used to monitor the system in the same
manner as the cycle switch.
1.3.2.8 Spindl-Gard Spray Nozzle. The basic nozzle can be
installed in heads with walls up to 1-3/4 inches (44.4
mm) thick. It has separate 1/8 inch NPT inlet ports for air
and oil. Nozzle design and system air pressure (15 psi
(1 bar) at nozzle inlet) combine to provide a 60 degree
conical spray pattern.
1.3.2.9 Soft-Seat Check Valve. This valve, installed at the
bearing point, prevents oil drainage of the oil lines and
prevents air from entering the oil lines. An optional use
is installing the check valve at the lube inlet of the spray
nozzle.
1.3.2.10 2-psi Relief Valve. Installed at the lowest point of
the machining head gear cavity, this valve serves the
following functions:
It maintains a positive internal head pressure to•
prevent coolant and other contaminants from
entering the head.
By relieving at 2 psi, it prevents build-up of•
excessive pressure which could interfere with
proper oil dispersion.
It keeps the gear cavity dry by providing a simple•
means to drain off oil that would otherwise collect.
1.3.2.11 Pressure Switch. An optional 1-psi pressure switch
mounted to the machine head can be used to detect
changes in air pressure within the machining head cavity
due to broken air lines, clogged spray nozzles or worn
seals.
1.3.3 SG-1 Operation
NOTE: Refer to Figure 1-1 for item numbers referenced in the
descriptive paragraphs below.
1.3.3.1 The pump (1), and controller (3) are mounted on an
easily accessible part of the machine. The controller
energizes the pump at predetermined intervals to supply
lubricant to the system. The divider valve (7) with cycle
switch or proximity switch (4) supplies lubricant to either
spray nozzles or terminating lube points. The cycling of
the divider valve is monitored by the controller through
an electrical signal generated by either the cycle switch
or proximity switch. A pump failure, power failure, loss of
lubricant, plugged or crushed lube line, or broken supply
line would prevent the cycle switch or proximity switch
from producing the required signal to the controller,
which would register a fault condition.
1.3.3.2 The spray nozzle (9), supplied with constant clean dry
air (approximately 40 ºF (4.4 ºC) dewpoint, 5-micron
absolute filtration, at 15 psi (1 bar)), pressurizes the
machining head and supplies intermittent lube in the
form of a spray to the gears and bearings in the machine
head cavity. Air consumption is 0.6 scfm (17 sclm) per
nozzle. A relief valve (10) inserted at the lowest point
of each machining spindle cavity maintains positive air
pressure at 2 psi (0.14 bar). It also provides a simple
means to drain off any collected oil in the machine head

Spindl-Gard SG-1 and SG-2 Systems
1-4
L42110
cavity. Soft-seat check valves (8) must be installed at the
end of any line coming out of the divider valve that will
be delivering oil directly to terminating lube points. These
checks prevent oil drainage from, or air entrance into, the
oil lines.
1.4 SG-2 COMPONENTS AND OPERATION
OVERVIEW
1.4.1 General: SG-2 differs from SG-1 (para 1.3) primarily in
lube delivery method and in the components used to
mix and deliver the oil and air to the bearings. Instead of
lubricating with discrete shots of oil spray, SG-2 supplies
continuous, minute oil droplets to bearings. By using
various options such as cycle switch and air flow switch,
the system can give warnings of improper operation
which could result in machining head damage. A typical
SG-2 system is illustrated in Figure 1-2.
1.4.2 SG-2 Components
1.4.2.1 General. Paragraphs 1.4.2.2 through 1.4.2.4 provide
a brief description of components used in typical SG-2
systems. The SG-2 uses the same controllers, pump
package, filters, divider valve, cycle switch and check
valves that are used in SG-1 (para 1.3). Air requirements
are 30 psi (2.1 bar) when no air switch is used or 60 psi
(4.2 bar) with air flow switch. In either case, supplied air
must have a 40 ºF (4.4 ºC) dewpoint and be filtered to 5
micron absolute. Components unique to SG-2 are listed
in paragraphs below.
1.4.2.2 Spindl-Gard Air Flow Switch. This small, simple
pneumatic device warns of any blockage or breaks in
the air line supplying the Spindl-Gard System. Normally-
open and normally-closed contacts on two air pressure
switches can be connected to the controller to provide
immediate fault feedback. The Spindl-Gard air flow
switch is preset at the factory, but may be adjusted if
necessary. The air flow switch can monitor up to three
nozzle assemblies.
1.4.2.3 Mixing Tee. The mixing tee receives metered oil from
the divider valve and air from the air flow switch at two
separate inlet ports. One common outlet port provides
the air/oil mix into a delivery line which connects to the
nozzle tube. Up to nine mixing tees may be coupled for
ease of mounting and plumbing if more than one nozzle
assembly is used. The mixing tees must be installed
vertically so that the oil inlet is at the top and the lube/air
outlet is at the bottom.
1.4.2.4 Spindl-Gard Nozzle Assembly. Several spray noz-
zle configurations are available. These options consist
of either of two tubes used with a threaded adapter or
an easy to replace bolt-in-place adapter. The easy to
replace adapter permits nozzle removal without affecting
the depth or direction of the spray orifice. A third type,
a restrictor assembly, consists of a fitting with 1/8 NPT
threads which thread into the machining head wall. A
0.030 inch (0.76 mm) orifice pressed-in fitting provides
an oil outlet at the restrictor end. The tube and adapter
assemblies consist of a cut-to-length tube which is
inserted into an adapter. The adapter threads or bolts
directly into the machining head wall. The tube is cut to
a length and flared to allow it to be held in the adapter
with its end inserted in the bearing housing. One tube
has a single outlet on the side while the second has two
side outlets located 180 degrees from each other. Details
of installing the tube are included in Section 2 of this
manual. Each Spindl-Gard nozzle consumes 0.6 scfm (17
sclm) of air.
1.4.3 SG-2 Operation
NOTE: Refer to Figure 1-2 for item numbers referenced in the
descriptive paragraph below.
1.4.3.1 The pump (1), and controller (3) are mounted on an
easily accessible part of the machine. The controller
energizes the pump at predetermined intervals to supply
lubricant to the system. Oil entering the divider valve (7)
is precisely metered and ported to the mixing tees (9).
The air flow switch (11) monitors the air supplied to the
mixing tees. Air from the air flow switch is also ported
to the air-oil mixing tees. The air and oil combine in the
mixing tees and are delivered through the air/oil delivery
tube to the nozzle assembly (10). When oil enters the
delivery tube, it is deposited on the inner surface,
forming a laminar sublayer along the walls. The dynamic
forces of the air moving through the center of the tube
move the oil to the nozzles orifice. The oil is continuously
sprayed in very small amounts on the rotating bearing
surface.
1.4.3.2 The SG-2 System is designed to operate in conjunction
with the divider valve’s cycle indicator pin and cycle
switch (4) accessories. By monitoring the cycle switch
with a controller, a fault warning signal can be generated
when the divider valve is not properly cycled. The air flow
switch adds fault warning when the air line or lines are
blocked or broken or the orifice is clogged. Dual sensing
elements in the air flow switch detect an increase or
decrease in the air flow rate and provides a fault signal
to the controller. When line monitoring is not desired,
the air flow switch is not used and an air supply line (30
psi (2.1 bar)) comes directly into the mixing tee. Air and
oil are mixed in the tee and delivered to the nozzle via
the air/oil delivery tube from the tee’s outlet port. When
multiple tees are combined together to form a manifold,
plugs are removed from all but the last tee and a single
air input line is used. Each tee in the manifold, however,
requires a separate oil line from the outlet of the divider
valve, and delivers oil to its specific nozzle-tube via a
single line from its outlet port.

1-5
Spindl-Gard SG-1 and SG-2 Systems L42110
/(1-6 Blank)
Figure 1-2. SG-2 System

2-1
Spindl-Gard SG-1 and SG-2 Systems L42110
2.1 GENERAL
2.1.1 In order to specify the correct components for any
particular system, a design process was completed
by either plant personnel or a Graco®distributor
representative. The design process determined the type
and placement of nozzles, identified location of bearings,
and of divider valve sizes. Obtaining the information from
the design process makes installing the system easier
and may help avoid confusion.
2.1.2 Installation of some system components requires drilling
and tapping of the machining head walls.
CAUTION: A set of machining head prints should be used to
ensure that no internal components are damaged during this
procedure.
2.2 SG-1 SYSTEM INSTALLATION
2.2.1 General: Paragraphs 2.2.2 through 2.2.8 discuss
the installation and mounting of components of SG-1
systems. Paragraphs 2.2.9 and 2.2.10 discuss the final
pneumatic and lube line connections which complete the
installation process. The information provided in these
paragraphs is designed to apply to all applications. For
information on the specific system, refer to information
obtained from the design process. For reference during
the following paragraphs, Figure 2-1 shows a sample
machining head with some of the SG-1 components
mounted. Actual mounting position of most components
will vary between systems.
2.2.2 Spray Nozzle Installation
2.2.2.1 The spray nozzle used in SG-1 systems has a 1-12 UNF
thread along the portion that threads into the machining
head walls. A locknut is used to secure the nozzle in
position once the nozzle is properly positioned in the
wall. Figure 2-2 shows SG-1 sample installations with
the machine head mounted in a horizontal and vertical
orientation.
2.2.2.2 The procedure for installing the spray nozzle is as
follows:
Mark the location of spray nozzle installation asa.
determined during system design.
CAUTION: Before drilling into walls, obtain machining head prints
to locate internal components. Avoid striking gears, bearings or
shafts during drilling.
Drill a 0.922 inch (23.42 mm) hole in spray nozzleb.
location.
Tap hole to 1-12 UNF.c.
Make sure locknut and thread seal are installedd.
on spray nozzle. Thread spray nozzle into tapped
hole until the spray tip is at the required depth. The
required depth will vary between Systems but is
generally designed to provide the widest expanse of
coverage possible with the 60 degree spray pattern.
Make sure that the spray nozzle will not contact any
gears when installed.
SECTION 2
INSTALLATION GUIDELINES
2.1 GENERAL .......................................................................... 2-1
2.2 SG-1 SYSTEM INSTALLATION............................................ 2-1
2.2.1 General ................................................................. 2-1
2.2.2 Spray Nozzle Installation........................................ 2-2
2.2.3 Terminating Lube Point Preparation ....................... 2-4
2.2.4 Relief Valve Installation.......................................... 2-4
2.2.5 Divider Valve Installation........................................ 2-4
2.2.6 Pump Package and Header Installation.................. 2-5
2.2.7 Pneumatic Control Package Installation ................. 2-5
2.2.8 Electrical Requirements......................................... 2-5
2.2.9 Pneumatic Connections......................................... 2-5
2.2.10 Lube Line Connections ........................................ 2-5
2.3 SG-2 SYSTEM INSTALLATION............................................ 2-6
2.3.1 General ................................................................. 2-6
2.3.2 Nozzle Tube Installation ......................................... 2-6
2.3.3 Air/Oil Mixing Tee................................................... 2-7
2.3.4 Divider Valve Installation........................................ 2-8
2.3.5 Air Flow Switch Installation.................................... 2-8
2.3.6 Pump Package and Header Installation.................. 2-9
2.3.7 Pneumatic Control Package Installation ................. 2-9
2.3.8 Electrical Requirements......................................... 2-9
2.3.9 Pneumatic Connections......................................... 2-9
2.3.10 Lube Line Connections ...................................... 2-10
OPERATION AND
SERVICE INSTRUCTIONS

2-2
Spindl-Gard SG-1 and SG-2 Systems L42110
With spray nozzle installed at required depth,e.
tighten locknut to keep the nozzle in position.
Make sure air and lube ports on top and sides of
spray nozzle are not obstructed by machining head
components.
If optional soft-seat check valve is used on thef.
spray nozzle, install check valve in lube port on top
of nozzle.
2.2.3 Terminating Lube Point Preparation
2.2.3.1 Some bearings located at the ends of shafts may be
recessed too far in the wall for the spray pattern to
provide adequate lubrication. For these cases, lubricant
is provided directly to the bearing from the divider valve.
It may be necessary to drill passageways to reach these
lubrication points. Figure 2-3 shows a typical machined
passageway. In the example shown, the front bearing
would not be exposed to lubricant from the spray nozzle.
By drilling access holes to the bearing and providing
a 1/8-27 NPSF hole for a soft-seat check valve, a line
directly from the divider valve can supply the bearing
with the proper amount of lubricant. Information from
the design process should locate any bearings which
need this treatment.
2.2.3.2 All inward-facing lip seals on the shaft should be
reversed to face outward. Reversing the inward-facing
seal reduces the possibility of contaminants entering the
head. Figure 2-4 shows a typical seal arrangement on a
vertical spindle shaft. Horizontal shafts require the same
treatment.
NOTE:
If only one lip seal is used on a shaft, the seal•
must face outward. Removal of one lip seal is only
permitted if two seals are used in the equipment.
Retaining springs must always be used.
If shaft is equipped with labyrinth or bronze seals,•
extra air flow may be required to make up for
excessive air loss. Contact a Graco representative
for special procedures if labyrinth or bronze seals
are used.
2.2.4 Relief Valve Installation
2.2.4.1 A 2 psi (0.14 bar) relief valve is installed at the lowest
point of the machining head gear cavity. The relief valve
has a male inlet thread and a female outlet thread, both
3/8 NPT. The procedure for installing the relief valve is
Figure 2-1. Spindl-Gard Installation

2-3
Spindl-Gard SG-1 and SG-2 Systems L42110
Figure 2-2. Typical Spray Nozzle Installation
HORIZONTAL HEAD APPLICATION
VERTICAL HEAD APPLICATION

2-4
Spindl-Gard SG-1 and SG-2 Systems L42110
as follows:
Use spindle prints to determine lowest point wherea.
oil may collect.
Drill a 0.562 inch (14.29 mm) hole in relief valveb.
location.
Tap hole to 3/8-18 NPT.c.
Install relief valve in tapped hole.d.
2.2.4.2 Approximately 1 gallon (3.785 liters) of oil will drain from
the relief valve for every 200 hours of spindle operation.
A drain line should be connected to the outlet of the
relief valve to direct the drainage to a safe collection
point.
2.2.5 Divider Valve Installation
2.2.5.1 Divider valves are used on both SG-1 and SG-2 systems
to provide the required amount of lubricant to bearings
or nozzles. Divider valves should be mounted vertically
with inlet up and on a flat surface in an accessible area.
Locate the valve in such a manner that tubing used to
connect the valve to the bearings or nozzle is kept to a
minimum length. Divider valves have four 0.281 inch
(7.14 mm) holes for mounting with 1/4-20 or 6 mm
screws. The holes are horizontally spaced 1.75 inches
(44.45 mm) apart. Vertical spacing of mounting holes
varies with the number of divider valve sections. Use all
mounting holes to ensure the valve is secure.
2.2.5.2 In some applications more than a single divider valve
may be used. Divider valves which are supplied lubricant
directly from the pump or header line are referred to
as master or primary divider valves. Divider valves
which receive lubricant from a primary divider valve are
referred to as secondary divider valves. Installation is
identical for all divider valves. Generally, divider valves
supplying Spindl-Gard components are primary divider
valves. Secondary valves are usually designed to provide
lubricant to terminating bearing points on the system.
Cycle switches or proximity switches can be installed
on each secondary divider valve assembly for expanded
monitoring and ease of troubleshooting.
2.2.6 Pump Package and Header Installation
2.2.6.1 For all systems, the pump package should be securely
mounted in an accessible location. Enough clearance
should be present to allow personnel to refill the reser-
voir without removal of any components.
2.2.6.2 For systems which use a pump-fed header, the header
line should be angled slightly upward from the pump
to assist in bleeding operations (see Figure 2-5). It is
recommended that a needle valve be located at the
highest point of the header line to allow for easier air
bleeding.
2.2.7 Pneumatic Control Package Installation
2.2.7.1 The air requirements for spray nozzles are 15 psi (1
bar) with 40 ºF (4.4 ºC) dew point. Air must be filtered
to 5 microns to avoid contamination. Each spray nozzle
utilizes 0.6 scfm (17 sclm) of air.
2.2.7.2 Air preparation packages should be mounted as close as
possible to their corresponding components in order to
minimize air line lengths. Excessive air line length could
result in pressure drop and erratic operation.
Figure 2-3. SG-1 Typical Machining Head Modification Figure 2-4. Reversing Seals

2-5
Spindl-Gard SG-1 and SG-2 Systems L42110
2.2.8 Electrical Requirements: Electrical components such
as cycle switches, air flow switches, zero-leak valves,
etc., have 1/2 NPT ports for installation of the necessary
conduit fittings according to plant procedures. Refer to
schematics provided with the controller to determine
proper wiring connections. Mount the controller in an
accessible location where connecting wiring does not
pose a hazard.
2.2.9 Pneumatic Connections: When all required components
have been installed, pneumatic connections may be
completed. When installing pneumatic tubing, avoid
severe bends or kinks which could deter air flow. Keep
all air lines along the contour of the machining head.
2.2.10 Lube Line Connections
2.2.10.1 When all required components have been installed, lube
line connections may be completed. Connections are
required to connect the divider valves to the pump or
header and to connect the divider valves to the spray
nozzles or lube points.
2.2.10.2 Various inlet and outlet port types are available on MSP
divider valves. Matching port types are available on
nozzles and accessories. Steel or copper tubing with 3/8
inch (9.5 mm) OD is recommended from pump or header
to the divider valves. Steel or copper tubing of 3/16 or
1/4 inch (4.8 or 6.4 mm) OD is recommended from the
divider valves to the lubrication points or spray nozzles.
When installing tubing, avoid sharp bends or kinks which
could deter lubricant flow. Keep all lube lines along the
contour of the machining head.
2.3 SG-2 SYSTEM INSTALLATION
2.3.1 General: Paragraphs 2.3.2 through 2.3.8 discuss
the installation and mounting of components of SG-2
systems. Paragraphs 2.3.9 and 2.3.10 discuss the final
pneumatic and lube line connections which complete the
installation process. The information provided in these
paragraphs is designed to apply to all applications. For
information on the specific system, refer to information
obtained from the design process.
2.3.2 Nozzle Tube Installation
2.3.2.1 Several different styles of nozzle tubes are available;
double-outlet, single-outlet and restrictor outlet. Figure
2-6 shows typical applications for each style. Typically,
one nozzle is required for each front or rear bearing
group. The orifice(s) at the nozzle tip are directed toward
the rolling element below the bearing cage assembly.
To avoid excess buildup of lubricant around the bearing,
drain holes need to be provided at the low point of each
bearing pocket.
2.3.2.2 Prior to installation of the nozzle tube (refer to paragraph
2.3.2.3) the machining head requires modification as
follows:
CAUTION: Before drilling into or disassembling machining head,
obtain prints to verify location of all drilling procedures. Thoroughly
remove all debris and chips after drilling to avoid possibility of
contamination.
NOTE: The following procedure is for installation of nozzle tube
assemblies. If your application uses the restrictor nozzle, complete
steps “a” and “b”, then tap the machining head to 1/8 NPT.
Disassemble machining head to the point necessarya.
for bearing removal.
Figure 2-5. Pump and Header Installation

2-6
Spindl-Gard SG-1 and SG-2 Systems L42110
Mark the location where the nozzle is to beb.
installed, as determined during system design.
Drill a 0.187 inch (4.75 mm) through the wall to thec.
bearing point.
NOTE: Steps “d” and “e” do not apply to the easy to replace nozzle
assembly. If this assembly is used proceed to step f.
Using hole drilled in step “c” as a pilot, drill a 0.516d.
inch (13.1 mm) hole as deep as possible without
breaking through the machining head wall.
Tap 0.516 in (13.1 mm) hole to 9/16-18 UNFe.
For easy to replace nozzle assembly, 484-090-f.
193, omit steps “d” and “c” and drill 19/32 inch
(15.08 mm) clearance hole as deep as possible
without breaking through head wall. Using adapter
mounting plate as a template, drill and tap two 1/4-
20 holes for attaching screws.
Drill a minimum 1/8 inch (3.2 mm) hole through theg.
machining head beneath each bearing pocket to
allow for drainage.
Assemble machining head.h.
2.3.2.3 Installation of the nozzle tube requires that the
machining head preparation steps be completed as
discussed in paragraph 2.3.2.2. Nozzle tubes are
shipped in 10-inch lengths and must be cut to proper
length for each installation. Figure 2-7 shows a typical
installation of a nozzle tube and should be referred to
during the following procedure:
Determine length of nozzle tube required bya.
reviewing machining head prints. This is dimension
“L” on Figure 2-7 Allow 0.625 inch (15.9 mm)
extra length for flare and internal length on nozzle
assemblies.
CAUTION: When flaring nozzle tube, use extreme care to avoid
splitting the lip of the flare.
Cut nozzle tube to desired length with cutoff wheel.b.
Using a modified flare tool 485-000-090, flare
nozzle tube to a 45 degree angle and 0.190 inch
diameter.
Remove flare nut and oil nozzle retainer from body.c.
Oil nozzle retainer has a 0.125 internal hex for
removal with an allen wrench.
Insure free-air-flow through nozzle tube; then installd.
it in body and secure with oil nozzle retainer. Note
that nozzle tube cross section is D-shaped and will
only enter body one way. Notches on hex portion of
body indicate outlet hole position.
Place locknut and thread seal on body and installe.
body into 9/16-18 UNF hole in machining head.
Figure 2-6. Nozzle Tube Applications

2-7
Spindl-Gard SG-1 and SG-2 Systems L42110
Thread body into machining head until nozzle tube
outlet(s) is/are at correct depth. Make sure notch on
body is directed toward bearing location.
Secure body in place with locknut.f.
Install flare nut on body for safekeeping. Flare nutg.
is used during lube line installation discussed in
paragraph 2.3.10.
2.3.3 Air/Oil Mixing Tee
2.3.3.1 One air/oil mixing tee is required for each nozzle used
in an SG-2 system. Each mixing tee is equipped with a
single 0.281 inch (7.14 mm) mounting hole. If more than
one mixing tee is used, tie rods are available to couple up
to four mixing tees together in a single manifold unit.
CAUTION: If an air flow switch is used at a given application, only
three mixing tees may be coupled with tie rods. If more than three
mixing tees are provided air from a single air flow switch, the
pressure differential caused by a blocked or broken air line may
not be great enough to actuate the switch.
2.3.3.2 Figure 2-8 shows a sectional view of the mixing tee. For
installation, the lube inlet should always be positioned at
the top. This allows the oil to flow through oil tube (8) and
properly enter outlet fitting (9) where air is mixed with the
oil to create the laminar flow in the air/oil delivery tube.
Air and lube inlet ports are 1/8-27 NPSF. If mixing tees
are to be grouped together, remove plugs (7) from all but
the last tee. Roll pin (1) ensures that all tees are aligned
while o-ring (10) provides proper sealing for grouped
tees.
2.3.3.3 The air/oil delivery tube requires 0.125 inch (3.18 mm)
internal diameter and a minimum length of 2 feet (61 cm)
of tubing from the outlet fitting to the nozzle tube.
NOTE:
The outlet fitting used on mixing tees is specially•
designed to provide proper air/oil flow through
the tube. Outlet fitting must not be replaced with
standard commercial fittings.
The air/oil delivery tube requires a 45 degree•
inverted flare to seal properly in the nozzle tube
assembly.
Use only Graco-supplied nut on outlet fitting. Do not•
use compression fittings.
Always install an external check valve at the lube•
inlet of the mixing tee.
2.3.4 Divider Valve Installation: Installation of divider valves
for SG-2 systems are similar to those used on SG-1
systems. Refer to paragraph 2.2.5 for SG-1 divider valve
installation.
2.3.5 Air Flow Switch Installation
2.3.5.1 The air flow switch monitors air flow to the mixing tees.
If an air line becomes plugged or broken, the decrease
or increase of air flow causes an increase or decrease of
air pressure. Pressure switches mounted in the air flow
switch enclosure detect the varied pressure and provide
a fault signal to the system controller.
2.3.5.2 One air flow switch can monitor up to three nozzle
assemblies. The switch should be positioned to keep the
distance between the air flow switches and the nozzle
assemblies to a minimum. Air flow switches are equipped
with two 0.281 inch (7.14 mm) mounting holes. Remove
the top cover to gain access to the mounting holes.
Figure 2-9 shows the air flow switch with cover removed.
The GAUGE port, located on the side of the unit, may be
connected to a gauge to allow visual monitoring of the air
pressure or as an alternate air inlet. This port is factory-
shipped with an 1/8-27 NPT plug installed. Remove the
plug to install a gauge. If this port is used as an alternate
air inlet, plug the hole marked AIR INLET.
2.3.5.3 Installation procedures for the air flow switch are as
follows:
Remove top cover to gain access to the twoa.
mounting holes.
Position the air flow switch in a location protecting itb.
from coolant spray.
Figure 2-7. Nozzle Tube Installation

2-8
Spindl-Gard SG-1 and SG-2 Systems L42110
Mark the position of the mounting holes.c.
Drill and tap the mounting holes for either 1/4-20 ord.
6 mm socket-head screws.
NOTE: Depending on the type of fittings used on the OUT and
GAUGE ports, it may be necessary to install fittings and orient them
in the proper direction before mounting the switch on the
machining head.
NOTE: Depending on the type of fittings used on the OUT and
GAUGE ports, it may be necessary to install fittings and orient
them in the proper direction before mounting the switch on the
machining head.
Secure air flow switch with two mounting screws.e.
Install cover on air flow switch and secure with fourf.
cover screws.
NOTE: Air flow switches may require adjustment for some
applications. Adjustment can only be accomplished after all
pneumatic connections have been completed. Refer to paragraph
2.3.9.4 for air flow switch adjustment procedures.
2.3.6 Pump Package and Header Installation: Installation
of pump packages and headers for SG-2 systems are
similar to those used on SG-l systems. Refer to para-
graph 2.2.6 for pump package and header installation.
2.3.7 Pneumatic Control Package Installation
2.3.7.1 The air requirements for mixing tees are 30 psi (2.1 bar)
with 40 ºF (4.4 ºC) dew point, filtered to 5 micron to avoid
contamination. If air flow switches are used, inlet air to
the switch should be 60 psi (4.2 bar) with the same dew
point and filtration requirements.
2.3.7.2 Air preparation packages should be mounted as close as
possible to their corresponding components in order to
minimize air line lengths. Excessive air line length could
result in pressure drop and erratic operation.
2.3.8 Electrical Requirements: Electrical components such
as cycle switches, air flow switches, etc., have 1/2 NPT
ports for installation of the necessary conduit fittings
according to plant procedures. Refer to schematics
provided with the controller to determine proper wiring
connections. Mount the controller in an accessible
location where connection wiring does not pose a hazard.
2.3.9 Pneumatic Connections
2.3.9.1 General. When all required components have been
installed, pneumatic connections may be completed.
When installing pneumatic tubing, avoid severe bends or
kinks which could deter air flow. Keep all air lines along
the contour of the machining head.
2.3.9.2 Air Flow Switches and Mixing Tees. Figure 2-10
represents a typical arrangement of air flow switches
and mixing tees. Inlet ports on the mixing tees are 1/8-27
NPSF. Both inlet and outlet ports on the air flow switches
are 1/8-27 NPSF Tubing from the air package to the air
flow switch and from the air flow switch to the mixing
tee should be 0.375 inch (9.52 mm) diameter. If air flow
switches are not used, up to four mixing tees could be
grouped together and provided with a single air inlet.
2.3.9.3 Mixing Tee to Nozzle Tube. Tubing from the mixing tee
outlet to the nozzle tube must be 0.187 inch (4.75 mm)
outer diameter with 0.125 inch (3.18 mm) inner diameter.
This size tubing is required to ensure the system creates
the laminar flow necessary for correct operation. Both the
mixing tee outlet and the nozzle tubes are equipped with
the correct sized fittings to install this tubing. A minimum
length of 2 feet (61 cm) is required for mixing tee to
nozzle tube tubing.
2.3.9.4 Air Flow Switch Adjustment. When pneumatic
connections have been completed the air flow switch
should be adjusted to the specific installation. Refer to
Figure 2-10 for adjustment screws mentioned in the
following adjustment procedure.
Attach pressure gauge in GAUGE port on air flowa.
switch.
Remove cover from air flow switch.b.
Adjust air regulator supplying the air flow switch toc.
60 psi (4.2 bar). Air should be flowing from the spray
nozzles.
Pressure gage on air flow switch should read 30 psid.
(2.1 bar). If pressure is incorrect, turn air adjustment
screw clockwise to decrease pressure or counter-
Figure 2-8. Mixing Tee

2-9
Spindl-Gard SG-1 and SG-2 Systems L42110
clockwise to increase pressure.
Adjust switch A to detect a low pressure (high flowe.
or broken line) condition. Switch A is factory set to
actuate when pressure on gauge falls to 23 psi (1.56
bar). Turning adjustment screw clockwise increases
actuating point, counterclockwise decreases.
Adjust switch B to detect a high pressure (low flowf.
or blocked line) condition. Switch B is factory set
to actuate when pressure on gauge rises to 37 psi
(2.52 bar). Turning adjustment screw clockwise
increases actuating point; counterclockwise
decreases.
2.3.10 Lube Line Connections
2.3.10.1 When all required components have been installed
lubricant connections may be completed. Connections
are required to connect the divider valves to the pump or
header and to connect the divider valves to the mixing
tees.
2.3.10.2 Various inlet and outlet port types are available on MSP
divider valves. Matching port types are available on
mixing tees and accessories. Steel or copper tubing with
3/8 inch (9.5 mm) OD is recommended from the pump
or header to the divider valves. Steel or copper tubing of
3/16 or 1/4 inch (4.8 or 6.4 mm) OD is recommended
from the divider valves to the lubrication points or mixing
tee. Steel or copper tube of 3/16 inch OD x 0.030-0.032
wall (4.8 x 0.79 mm), 24 inch (609.6 mm) minimum
length is required between the mixing tee and nozzle.
When installing tubing, avoid sharp bends or kinks which
could deter lubricant flow. Keep all tubing runs along the
contour of the machining head.
Figure 2-9. Air Flow Switch Installation

2-10
Spindl-Gard SG-1 and SG-2 Systems L42110
Figure 2-10. Air Flow Switch and Mixing Tees

3-1
Spindl-Gard SG-1 and SG-2 Systems L42110
3.1 GENERAL
3.1.1 This section contains information used to start and
operate a typical Spindl-Gard system. The areas of
coverage are as follows:
System filling and bleeding procedures, which•
describe how to remove air from any Spindl-Gard
system. Refer to paragraph 3.2.
Daily start-up procedures for SG-1 and SG-2. Refer•
to paragraph 3.3.
Operation of SG-1 and SG-2 system. Refer to•
paragraph 3.4.
Shutdown procedures for SG-1 or SG-2. Refer to•
paragraph 3.5.
3.1.2 Proper start-up and operation of any Spindl-Gard
system depends upon correct installation of the
system components. Refer to Section 2 for installation
guidelines. Incorrectly sized tubing or improperly installed
components can have adverse effects on a Spindl-Gard
system.
3.2 SYSTEM FILLING AND BLEEDING
3.2.1 General
3.2.1.1 To ensure air-free operation of the system, all supply
tubing and divider valves must be filled with oil before
system start-up. Typically, a system receives oil in one of
two ways as follows:
Oil from a supply pump is delivered to a master•
divider valve which delivers to either a secondary
divider valve, to the dispensing nozzle, or to
terminating lube points.
A supply pump provides oil to a header which•
feeds one or more master divider valves which may
provide oil to either secondary dividers, dispensing
nozzles or terminating lube points. In this case the
master divider valves are usually equipped with a
zero-leak valve to allow independent lubrication of
each area receiving lubricant.
3.2.1.2 The filling and bleeding operation is separated into
several major procedures as follows:
Initial Adjustments (para 3.2.2)•
Bleeding Secondary Divider Valves (para 3.2.3)•
Bleeding Pump-Supplied Master Divider Valve (para•
3.2.4)
Bleeding Header-Supplied Master Divider (para•
3.2.5)
Verification of Properly Bled System (para 3.2.6)•
3.2.1.3 All procedures require the use of a hand pump or other
similar type of oil supply to fill the various system
components. Make sure that the hand pump is filled with
clean oil filtered to 10 microns. Make sure oil used for
system filling is the same as that used for lubrication
purposes.
SECTION 3
SYSTEM START-UP AND OPERATION
3.1GENERAL........................................................................... 3-1
3.2SYSTEM FILLING AND BLEEDING........................................ 3-1
3.2.1 General ................................................................. 3-1
3.2.2 Initial Adjustments................................................. 3-2
3.2.3 Bleeding Secondary Divider Valves ........................ 3-2
3.2.4 Bleeding Pump-Supplied Master Divider Valve....... 3-4
3.2.5 Bleeding Header-Supplied Master Divider Valve..... 3-4
3.2.6 Verification ............................................................ 3-5
3.3DAILY START-UP ................................................................ 3-5
3.3.1 General ................................................................. 3-5
3.3.2 Start-up Procedure, SG-1 ...................................... 3-5
3.3.3 Start-up Procedure, SG-2 ...................................... 3-5
3.4OPERATION........................................................................ 3-6
3.4.1 General ................................................................. 3-6
3.4.2 Output Adjustment................................................. 3-6
3.5SHUTDOWN ....................................................................... 3-6
OPERATION AND
SERVICE INSTRUCTIONS