Graco GBL 7500 User manual

Instructions

GBL 7500 Box Lubricator

Pump

GBL Shaft Rotation/Low Level

Alarm Pump 3A2257F

GBL 7500 Box Lubricator Pump: Fully enclosed, self-lubricating, precision, metering pump

capable of pumping small flows of either mineral or synthetic oil to machinery injection

points. For professional use only.

GBL Shaft Rotation/Low Level Alarm Pump: Fully enclosed, self-lubricating, precision,

alarm pump capable of sensing shaft rotation and oil low level. For professional use only.

3/16” models: 7500 psi (51.7 MPa, 517 bar) Maximum Working Pressure

1/4” models: 6000 psi (41.4 MPa, 414 bar) Maximum Working Pressure

3/8” models: 3500 psi (24.1 MPa, 241 bar) Maximum Working Pressure

Alarm Pump: 500 psi (3.4 MPa, 34.4 bar) Maximum Working Pressure

Models:

Suction Models

• 24J391 - 3/16”

• 24J392 - 1/4”

• 24J393 - 3/8”

Gravity Models

• 24J394 - 3/16”

• 24J395 - 1/4”

• 24J396 - 3/8”

Pressure Models

• 24J397 - 3/16”

• 24J398 - 1/4”

• 24J399 - 3/8”

Alarm Pump Model

• 24K466

Important Safety Instructions

Read all warnings and instructions in this

manual. Save these instructions.

Suction Model Shown

II 2G Ex hT6 Gb

Warnings

23A2257F

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-

tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When

these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and

warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may

look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treat-

ment.

• Do not point dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or

servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

FIRE AND EXPLOSION HAZARD

When flammable fluids are present in the work area, such as gasoline and windshield wiper fluid, be aware

that flammable fumes can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources, such as cigarettes and portable electric lamps.

• Keep work area free of debris, including rags and spilled or open containers of solvent and gasoline.

• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.

• Ground all equipment in the work area.

• Use only grounded hoses.

•Stop operation immediately if static sparking occurs or you feel a shock.Do not use equipment until

you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

Warnings

3A2257F 3

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system compo-

nent. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all

equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about

your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufac-

turer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create

safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye

injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not lim-

ited to:

• Protective eye wear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer

WARNING

Warnings

43A2257F

Pressure Relief Procedure

1. Stop lube pump.

2. If installed, close oil supply valve located upstream

from pump.

3. If installed, open drain valve located downstream

from the pump.

4. Slowly crack open fluid line fittings to relieve pres-

sure.

Installing the Pump

Grounding

Ensure the reservoir is properly grounded as the pump

is grounded through the mounting screws.

Mounting Pump

NOTE:

• Ensure box and lube system are sized appropriately

for the selected pressure.

• Ensure an appropriate pressure relief device, suit-

able for your application, is installed in the system.

• Inspect your box lubricator and replace any dam-

aged or worn components.

1. Ensure the pump mounting surface on the reservoir

cover is clean. Clean as needed.

2. Align gasket (a) with opening on the top of the reser-

voir cover making sure holes (b) on either end of the

gasket match mounting holes (c) in reservoir cover

(FIG. 1).

NOTE: Alarm Pumps Only - For optimum perfor-

mance, mount alarm pump in location furthest from

drive motor.

•For Gravity and Pressure Fed pumps, skip Step

3 and continue installation with Step 4.

•For Alarm pumps skip Step 3a and continue

installation with Step 3b.

•Pressure Fed pumps follow Step 3a and 3b.

3. For Suction Fed Pumps install pump inlet strainer:

a. Check length of suction tube. If it is too long to

fit in the reservoir, use a pliers to break off the

lower section of the tube (a) (FIG. 2).

Follow the Pressure Relief Procedure whenever

you see this symbol.

This equipment stays pressurized until pressure is

manually relieved. To help prevent serious injury from

pressurized fluid, such as skin injection, splashing

fluid and moving parts, follow the Pressure Relief

Procedure when you stop pumping and before

cleaning, checking or servicing the equipment.

The equipment must be grounded to reduce the risk

of static sparking. Static sparking can cause fumes to

ignite or explode. Grounding provides an escape wire

for the electric current.

FIG. 1

Setup

3A2257F 5

b. For all installations (whether the tube needs to

be trimmed or can be used without trimming),

press strainer onto end of the suction tube until

it “bottoms” (FIG. 3).

4. Orient pump so the roller bearing on the bottom of

the pump is aligned with the cam inside the reser-

voir.

5. Install pump on the reservoir by aligning the holes

(d) on either end of the pump with the mounting

holes (c) in the reservoir cover (FIG. 1).

6. Install washers (f) and bolts (e) and wrench tighten

them securely. Torque bolts as recommended in

your reservoir instruction manual.

Setup

1. Expel all air from pump and relieve pressure (page

4).

NOTE:

• Do not connect the oil line to the pump outlet or

lube point until all air has been expelled.

• Use filtered oil when priming the pump.

• Filter oil with minimum 25 micron strainer.

Machine requirements may require a higher

cleanliness level.

• Maximum allowable inlet pressure:

- Pressure Fed Pump: 100 psi (0.69 MPa, 6.9

bar)

- Gravity Fed Pump With Sight Glass: 10 psi

(0.07 MPa, 0.7 bar)

• Minimum required inlet pressure for priming:

- Pressure Fed Pump: 1 psi (0.007 MPa, 0.07

bar)

- Gravity Fed Pump: N/A

- Suction Fed Pump: N/A

- Alarm Pump: N/A

2. Prime the pump using the procedure described in

the following section that relates to your pump

model.

FIG. 2

FIG. 3

NOTICE

Any pressure applied to the pump inlet has the potential

to cause unrestricted flow from the pump outlet even in

a pump that is at rest or adjusted for zero stroke. To pre-

vent this from happening, install a check valve of a com-

parable pressure rating at the pump outlet.

NOTE: The internal “discharge check valve” does not

have a spring and is rated at zero psi.

Setup

63A2257F

Suction Fed Models (FIG. 4)

1. Remove the sight well plug (1) and outlet plug (5).

Discard outlet plug (5).

2. Fill the sight well (2) to the top with appropriately fil-

tered oil.

3. Operate the hand priming assembly (3) until the oil

level drops below the end of the drip tube (4).

4. Apply thread sealant (user supplied) to sight well

plug (1).

5. Replace the sight well plug (1), taking care to not

allow any thread sealant into the sight well (2).

6. Torque sight well plug (1) to 35 + 5 in. lbs (3.95 + 0.6

N.m).

7. Continue to hand prime until oil expelled from the

outlet (6) is free of air.

8. If all oil is evacuated from sight well (2), repeat steps

2 - 7 as often as necessary, until all air has been

expelled.

Gravity Fed Models (FIG. 5)

NOTE: In the following instructions, the fill line refers to

the inlet line.

1. Remove and discard the sight well plug (1) and out-

let plug (5).

2. Fill the sight well (2) to the top with appropriately fil-

tered oil.

3. Operate the hand priming assembly (3) until the oil

level drops below the end of the drip tube (4) (FIG.

4).

4. Apply thread sealant (user supplied) to fill line fitting.

5. Connect fill line to sight well (2), taking care to not

allow any thread sealant into the sight well.

6. Torque fill line fitting to 35 + 5 in. lbs (3.95 + 0.6

N.m).

7. If installed, open oil supply valve located upstream

from the pump.

8. Continue to hand prime until oil expelled from outlet

(6) is free of air.

9. If all oil is evacuated from sight well, repeat steps 2 -

8 as often as necessary, until all air has been

expelled.

FIG. 4

FIG. 5

Setup

3A2257F 7

Pressure Fed Models (FIG. 6)

NOTE: In the following instructions, the fill line refers to

the inlet line.

1. Remove and discard the inlet plug (1) and outlet

plug (5).

2. Apply thread sealant (user supplied) to fill line fitting.

3. Connect fill line to inlet (2).

4. Torque fill line fitting to 85 + 10 in. lbs (9.60 + 1.13

N.m).

5. If installed, open oil supply valve located upstream

from the pump.

6. Operate the hand priming assembly (3) until the oil

expelled from the outlet (6) if free of air.

Alarm Pump Models (FIG. 7)

1. Remove the sight well plug (1).

2. Fill the sight well (2) to the top with appropriately fil-

tered oil.

3. Apply thread sealant (user supplied) to sight well

plug (1).

4. Replace the sight well plug (1), taking care to not

allow any thread sealant into the sight well (2).

5. Torque sight well plug (1) to 35 + 5 in. lbs (3.95 + 0.6

N.m).

NOTE: Fluid is pumped from the reservoir, through a

manifold monitored by a check valve and pressure

switch, and then outputs the fluid back into the same

reservoir. The check valve should be set to a cracking

pressure of 95 to 105 psi (6.5 bar [0.65 MPa] to 7.2 bar

[0.72 MPa]). When the fluid pressure reaches this level,

the fluid travels past the check valve and back to the res-

ervoir.

If the shaft stops rotating or the fluid level is below the

suction tube, the pressure will bleed down to the pres-

sure switch set point until it reaches 0 psi (0 bar, 0 MPa).

The pressure switch should be set to 50 psi (3.4 bar

(0.34 MPa) to allow at least 45 seconds until the pres-

sure is reached and set off the alarm.

FIG. 6

FIG. 7

Setup

83A2257F

Connecting Lube Lines to Pump: Suction,

Gravity and Pressure Fed Pump Models

Only

NOTE: The lube line refers to the outlet line supplying

lubricant to the lubrication points.

1. Apply thread sealant (user supplied) to lube line fit-

ting.

2. Connect lube line to pump outlet (6), (FIG. 8)(also

see pages 15 and 16).

3. Torque lube line fitting to 50 + 5 in. lbs (5.65 + 0.6

N.m).

4. If installed, close the drain valve, located down-

stream from the pump.

5. Hand prime the pump until clean, air-free oil is flow-

ing through the lube line.

6. Connect the lube line to the lube point.

7. After startup, adjust individual pumps to meet

required flow rates. See Adjusting the Pump, page

Alarm Models Only: Installing Pressure

Switch (see Alarm Pump, page 17)

The pump’s check valve is monitored by a pressure

switch. When fluid pressure reaches the check valve

cracking pressure

1. Apply thread sealant (user supplied) to pressure

switch.

2. Install pressure switch into sensor output (3) (FIG.

7).

NOTE: Set switch to 50 psi (3.44 bar, 0.34 MPa).

3. Set the pumps’ check valve to a cracking pressure

of 95-105 psi (6.55 bar to 7.24 bar / 0.655 MPa to

0.724 MPa)

4. After startup, ensure switch is activating correctly.

Adjusting the Pump

Pump volume is controlled by an external adjusting

screw (8) (FIG. 9). Turning the adjusting screw changes

the length of the piston stroke which changes the pump

discharge volume.

1. Loosen the adjusting screw locknut (9) (FIG. 9).

2. Turn the adjusting screw (8) (FIG. 9):

• Counterclockwise - increases discharge volume

(drops per stroke)

• Clockwise - decreases discharge volume (drops

per stroke)

FIG. 8

FIG. 9

Setup

3A2257F 9

3. For Suction Fed and Gravity Fed models only:

With the lubricator operating, count the drops from

the drip tube (4) falling into the sight well (2) for one

minute.

The number of drops seen falling in the sight well equals

the amount of oil discharged by the pump. See Specifi-

cations, page 10 for additional information on converting

drops to volumetric output.

For Pressure Fed models only: Measure the output

volume at the lube point.

4. If any further adjustment is necessary, repeat Steps

2 and 3.

5. Once the pump is adjusted to the proper specifica-

tion, tighten the adjusting screw locknut (9) (FIG. 9).

NOTE: Piston stroke length set near zero may cause an

inconsistent flow.

Calculating Output Capacity

The number of drops observed falling in the sight well

equals the amount of oil discharged by the pump. The

pump volume can be adjusted using the adjusting screw

(8) (FIG. 9) to change the piston stroke. (See Adjusting

the Pump.)

Calculating Pints per Day

Calculating Minimum or Maximum Pump Output

Capacity in Pints per Day

* Minimum and Maximum drops per stroke listed in Specifications,

page 10.

Example:

The following example calculates the maximum and

minimum flow for a 1/4 inch pump model with an electric

motor and 300:1 gear ratio.

To calculate the Maximum Flow:

To calculate the Minimum Flow:

Replace the maximum 12 drops per stroke (used in the

equation above) with the minimum 2 drops per stroke =

1.17 minimum pints per day.

FIG. 10

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

PLQGD\

;

1XPEHURI'URSVLQD3LQW

3LQWV3HU'D\

,QSXW6SHHG

*HDU5DWLR

3XPS2XWSXW

0LQRU0D[

GURSVVWURNH



PLQGD\

;;

1XPEHURI'URSVLQD3LQW

0LQRU0D[

3XPS2XWSXW

3LQWV3HU'D\

1725 RPM

300:1 Gear Ratio

Max 12 drops

per stroke 1440 min.

14438(Number of Dropsin aPint)

=Max 6.88

Pints/day

Specifications

10 3A2257F

Specifications

Table 1

Drops per Stroke Table Section of Table Applies to Suction and Gravity Fed Models Only

• Allowable viscosity range independent of temperature: 80-5000 SUS.

• Strokes/Minute - Maximum - 50; Minimum - 3

• Stroke Length - Maximum 1/2 inch (12.7 mm)

†Refer to your manufacturer’s specific instruction manuals to ensure your box and lubrication system are rated for

the selected pressure.

1 Based on 500 SUS oil at 70°F ambient. Heavier oil will produce fewer but larger drops.

2When approaching maximum outputs, some oils will stream rather than form drops in sight glass.

Table 2

Fluid Measurement Conversion Data

Piston Diameter Max Outlet Pressure† Drops/Stroke1, 2 Cubic Inch/Stroke Cubic cm/Stroke

inches mm psi MPa bar Min* Max Min* Max Min* Max

3/16 4.76 7500 51.7 517 0 7 0 0.014 0 0.229

1/4 6.35 6000 41.4 414 0 12 0 0.024 0 0.393

3/8 9.53 3500 24.1 241 0 27 0 0.054 0 0.885

* Pump adjusted to zero stroke

Fluid Measurement Conversion Data

(NOTE: All measurements are approximate values only)

# of Drops US Measurement Metric Measurement

1 drop 0.002 cubic inch 0.033 cubic centimeter (cc)

14,438 drops 1 pint 0.47 Liter (l)

28.875 cu. inch 1 pint 0.47 Liter (l)

500 drops 1 cubic inch 16.39 cubic centimeter (cc)

10 drops/minute 1 pint/24 hours 0.47 Liter (l)/24 hours

30 drops 0.061 cubic inch 1 cubic centimeter (cc)

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