Provides a continuous, precise and temperature independent supply of grease or oil
lubrication to all lubrication points of sliding- and roller bearings, drive- and transport
chains, sliding guideways, open gears and seals. For professional use only.
Not approved for use in European explosive atmospheres.
75 psi (0.5 MPa, 5 bar) Maximum Working Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
EN
See page 5 for model information.
WARNINGWARNINGWARNING
WARNING
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation 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.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system
can cause electric shock.
•Turn off and disconnect power at main switch before disconnecting any cables and
before servicing equipment.
•Connect only to grounded power source.
•All electrical wiring must be done by a qualified electrician and comply with all local
codes and regulations.
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 sol-
vent 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.
•If there is static sparking or you feel a shock, stop operation immediately. Do not
use equipment until you identify and correct the problem.
•Keep a working fire extinguisher in the work area.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin,
inhaled, or swallowed.
•Read MSDSs to know the specific hazards of the fluids you are using.
•Store hazardous fluid in approved containers, and dispose of it according to applica-
ble guidelines.
23A0417D
PRESSURIZED EQUIPMENT HAZARD
WARNINGWARNINGWARNING
WARNING
Fluid from the equipment, leaks, or ruptured components can splash in the eyes or on
skin and cause serious injury.
• Follow the Pressure Relief Procedure before cleaning, checking, or servicing
equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts
immediately.
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 component. 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.
• 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 manufacturer’s replacement parts only.
• Do not alter or modify equipment.
• Do not puncture, open or take lubricator apart.
• 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.
3A0417D3
WARNINGWARNINGWARNING
WARNING
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in
the operating area of the equipment to help protect you from serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. This equipment includes
but is not limited to:
•Protective eyewear, and hearing protection.
•Respirators, protective clothing, and gloves as recommended by the fluid and sol-
vent manufacturer.
CALIFORNIA PROPOSITION 65
This product contains a chemical known to the State of California to cause cancer, birth
defects or other reproductive harm. Wash hands after handling.
D LED function display
E † Cover
F† Cable with plug
† Reusable parts
Component Identification
Wiring Diagrams
PLC Connection - One Output Signal
NOTICE
Incorrect connection of the lubrication unit
could destroy electronics.
63A0417D
PLC Connection - Two Output Signals
Component Identification
3A0417D7
Component Identification
PLC Connection - Three Output Signals
83A0417D
Installation and Setup
4
3
1
2
A
B
D
C
Installation and Setup
Pin Assignment
Pin
Assignment
1browncurrent +
2whiteLED green digital
3bluecurrent 4blackLED red digital
Pressure Relief Procedure
Cable
ColorSignal
Determining Correct Mounting
Method
NOTE:
•Direct mounting should be used for lubrica-
tion points that are easily accessible.
•Remote mounting is recommended if you
answer YES to any of the questions below.
1. Is the ambient temperature at the lubrication point higher than +50°C (122°F)?
2. Is it necessary to remove protective
screens, walls or other types of protection
in order to reach the lubrication point?
3. Is the lubrication point exposed to high
vibrations?
4. Is it difficult to access the lubrication point
during operation of the machine?
5. Is the lubrication point exposed to any of
the following:
1. Cover lubrication point (A) and lubricator
(B) with a heavy rag to absorb any fluid that
may leak out while loosening the adapter.
2. Carefully unscrew support adapter (D) from
the lubrication point (A).
A Lubrication Point
B Lubrication Canister
CDrive Unit
D Support Adapter
•water jets for high-pressure cleaning
machines?
•corrosive chemicals?
•extreme temperature?
•falling materials?
3A0417D9
Installation and Setup
A
B
aa
bb
cc
dd
ee
ff
Preparing Lubricator for
Installation
The lubricator has a self-protection mechanism which shuts off the drive unit at counter
pressures higher than 5 bar (72.5 psi). Most
bearings require 0.5 - 2 bar (7.2 to 29 psi)
pressure (without tubes, extensions, angles,
etc.).
Use the following procedure to check the
counter pressure of the application prior to
installation.
NOTE:
•Be sure to use a lubricant cartridge that
contains the same grease used in the
application.
•The best measurement results are
achieved during operation.
5. Install lubricator unit into
adapter (B).
6. Screw a pressure manometer into the lubrication point (dd) (FIG. 1).
A pressure manometer is a simple device that
measures pressure output. To build a pressure
manometer you need a pressure gage (aa),
tee fitting (bb) and stop valve (cc). FIG. 1
shows a correctly assembled pressure
manometer, connected to the lubricator and a
lubrication point.
Checking the Counter Pressure
1. Clean the lubrication point to remove any
potential contaminants.
2. Install reducers, extensions, grease line,
etc. (if necessary).
3. Prime the grease line and all accessories
with the same grease that is contained in
the lubricator. (See Parts, page 23 for a
complete list of available grease cartridges).
4. Remove the plug (A).
FIG. 1
aa
bb
cc
dd
ee
ff
Pressure Gauge
Tee Fitting
Stop Valve
Lube Point
Lubricator
ON / OFF Switch
7. Ensure the stop valve (cc) of the pressure
manometer is open.
8. Attach lubricator and adapter (B) to the
pressure manometer (aa - cc) and turn the
switch to “ON” (ff) (F
IG. 1).
103A0417D
Installation and Setup
9. Run the manometer for about 20 seconds.
Observe the gauge and repeat this procedure until the pressure registered on the
gauge stays constant.
10.To determine the counter pressure, wait
approximately 5 minutes until the system
has relaxed. Do one more discharge by
turning the unit OFF; then ON again until it
dispenses for no more than 5 seconds.
11.Wait approximately 5 more minutes to
make sure the system does not lose pressure and remains constant.
12.To disconnect lubricator from manometer,
follow pressure relief procedure provided on page 9.
NOTE: In this application, you will be disconnecting adapter (B) from manometer
instead of lubrication point.
Priming/Pre-filling Fittings and
Grease Lines
All accessories and grease lines must be
primed/pre filled. Without this priming/pre filling, the lubricator would first have to fill the
accessories with lubricant.
Example: A tube that is one meter long
requires about 28 cm
take the lubricator with a 12 month setting and
an EM-120 grease canister about 3 months to
fill this 1 meter tube.
FIG. 2 illustrates one way to pre fill using a
grease gun to dispense the grease.
FIG. 2
3
of lubricant. It would
NOTICE
Do NOT disconnect lubricator from adapter
(B). Screwing anything into end of lubricator a
second time will damage self-sealing threads.
13.If the counter pressure is 5 bar (72.5 psi) or
higher, flush the lubrication point with a
grease gun.
If the counter pressure does not decrease
you may need a different lubricant or size
lubricator canister. Contact Graco Customer service for assistance.
3A0417D11
Installation and Setup
12 34
C
A
B
D
E
Circuit Board Settings
Function Display
Red and green LED’s (Light Emitting Diodes) are on the circuit board and visible through the
transparent cover. The following signals about operating conditions/malfunctions are displayed
by these LED’s for the user:
LEDSignalMeaning
GreenSteadySystem functions OK
RedSteady for less than 30 seconds with
RedSteady signal for more than 30 sec-
Green and Red Steady signalLubricator unit is empty.
FIG. 3
ALED Red
BLED Green
C 4-way code switch
Lubricator is discharging
motor running
Malfunction / error
onds
Change canister.
Setting Dip Switches
1. Unscrew and remove the cover of the drive
unit.
2. Use a small screwdriver or your finger to
move dip switches to the desired position.
Refer to Table 1.
•Dip switches 1 and 2 marked “TIME”
are used to set the discharge amount
per 100 operating hours.
•Dip switches 3 and 4 marked “VOL” are
used to set the lubrication canister size.
If the 4-way code switch does not correspond to the actual size of the lubrication canister, it will lead to a wrong
signal and over or under lubrication.
D Plug connection
E Circuit board
123A0417D
TABLE 1: Dip Switch Settings
VOL
34
VOL
VOL
12
ON
TIME
ON
TIME
12
ON
TIME
ON
TIME
34
34
12
34
•Amount of discharge in cc (1cc = 0.9 gram lubricant) per 100 operating hours.
•White square indicates position of dip switch.
Installation and Setup
Canister
Size
Dip Switch
Position
12
EM-60EM-120EM-250
34
34
8.3316.6734.721 month continuous operation
2.785.5611.573 months continuous operation
1.392.785.796 months continuous operation
Discharge period
0.691.392.8912 months continuous operation
12
Determining proper dip switch settings to achieve optimal lubrication
In the “normal mode” (per 100 operating
hours).
Variation 1: 2.78 cc/100
hours for a 60 cc Lubrication
canister (EM-60).
Example:
A roller bearing is to be provided with 14 cc of
lubricant every 500 hours of operation: 14 cc
500 hours = 0.028 cc per hour = 2.8 cc per 100
hours.
Table 1 shows the 3 different settings that are
possible for each lubrication canister size.
Variation 2: 2.78 cc/100
hours for a 120 cc Lubrication
canister (EM-120).
Variation 3: 2.89 cc/100
hours for a 250 cc Lubrication
canister (EM-250).
12
12
3A0417D13
Installation and Setup
Correct
Incorrect
Selecting Mounting Location
Installation Guidelines
•Before installing the lubricator, the lubrica-
tion points and any extensions must be
adequately pre-lubricated with the same
lubricant contained in the lubricator. A 400
gram lubricant cartridge for grease guns is
available from Graco. See Parts, page 23
for a complete list of available lubricant cartridges.
•Install one lubricator per lubrication point.
•When oil is used for lubrication, a
non-return valve (oil throttle) must be
installed. This will prevent oil leakage from
the lubricator. An oil throttle, part number
124102 is available from Graco. See Parts,
page 23.
•For all metal to metal connections (i.e.,
extensions, reducers, etc.) make sure to
use LOCTITE® 243* (semi-tight screw lock-
ing).
*Loctite
ration.
®
is a registered trademark of the Loctite Corpo-
Direct Mounting Installation
Refer to FIG. 4 for examples of correct and
incorrect direct mounting installations.
•An oil-filled lubricator must be installed ver-
•For horizontal mounting a bracket clip must
•For vertical installations always use a sup-
•The grease nozzle of the lubricator has a
•Do not overtighten the plastic thread of the
tically (outlet down).
be used to hold the lubricator in place. A
horizontal clip bracket part number 124086
is available from Graco. See Parts, page
23
port adapter part number 124105 is available from Graco. See Parts, page 23.
npt 1/4 inch male thread. If your application
has a different thread you may need to use
an adapter. See Parts, page 23 for a complete list of available adapters.
lubricator.
FIG. 4
143A0417D
Installation and Setup
A
B
C
D
E
F
Remote Mounting Installations
Refer to FIG. 5 - FIG. 7 for examples of correct
remote mounting installations.
•Remote installations require a grease line.
Graco recommends using a 5/16 inch flexible hose.
•Select a position for the lubricator that is
easy to access and protected from
high-pressure water jets, falling materials,
corrosive chemicals and extreme temperatures.
Grease Lubrication with Tube
FIG. 5
A Clip, 124086
B Support adapter, 124105
C Bracket, 124087
D Tube connector (User supplied)
E Nylon tube (User supplied)
FTube connections (User supplied)
Must be at least 5/16 inch diameter tube.
3A0417D15
Installation and Setup
A
B
C
D
E
F
G
C
H
J
K
From-top-lubrication of a Chain with Oil
A Clip, 124086
B Support adapter, 124105
C Bracket, 124087
D Tube connector (User supplied)
E Nylon tube (User supplied)
FTube connections (User supplied)
G Oil throttle, 124102*
H L-Bracket, 124098
JBulkhead mounting plate, 124099
K Oil brush, 1”x 1.5”, 124090
*The non-return valve (oil throttle (G) should
always be placed at the lowest point of the
application.
Must be at least 5/16 inch diameter tube.
FIG. 6
163A0417D
Lubrication of Elevated Chain with Oil
F
E
A
B
C
G
D
Installation and Setup
FIG. 7
A Clip, 124086
B Support adapter, 124105
C Bracket, 124087
D Tube connector (User supplied)
E Nylon tube (User supplied)
FTube connections (User supplied)
G Oil throttle, 124102*
*The non-return valve (oil throttle: G) should
always be placed at the lowest point of the
application.
Must be at least 5/16 inch diameter tube.
3A0417D17
Installation and Setup
A
B
Installing Lubricator to
Lubrication Point
1. Clean the lubrication point to remove any
potential contaminants.
2. Verify the thread of the lubricator corresponds to the thread of the screw point.
3. Install reducers, extensions, grease line,
etc. (if necessary).
4. Verify Dip Switches are correctly set. See
Table 1, page 13.
5. Prime the grease line and all accessories
with the same grease that is contained in
the lubricator. (See Parts, page 23 for a
complete list of available grease cartridges).
6. Remove the plug (A).
8. Screw lubricator to lubrication point, hand
tight only.
NOTICE
To ensure optimal lubrication:
•Seal threads of all connecting parts with a
suitable, standard sealant.
•Mount oil filled lubricators properly with the
outlet pointing down.
•Never screw in the lubricator a second time
or the self-sealing threads will be damaged.
•For remote mounting installations, make
sure bracket does not squeeze the lubrication canister as this could block the piston
inside the canister.
7. Install lubricator unit
into adapter (B).
183A0417D
Operation
Operation
Before operation verify:
•The lubricator does not have any visible
damage.
•The lubricator canister is filled with the
requested grease or oil.
•For oil filled lubrication canisters, an oil
throttle must be attached.
•The “VOL” switches 3 and 4 of the 4-way
code switch match the correct size of the
lubrication canister.
•The “TIME” switches 1 and 2 of the 4-way
code switch in the drive unit match the
desired discharge period.
•All components are properly assembled
and screwed together hand tight.
To begin the discharge:
Plug power cable into lubricator (FIG. 8).
.
FIG. 8
During Operation:
•Carry out regular performance checks.
Check for possible leakages and the status
of the lubricator.
•Regularly monitor the fill-level of the trans-
parent lubrication canister.
3A0417D19
Changing the Lubrication Canister
B
A
B
Changing the Lubrication
Canister
When the red and green LED light up at the
same time, the lubrication canister is empty
and should be replaced.
NOTICE
The drive unit and circuit board must always
be protected from moisture to prevent damaging these components. Always change the
lubrication canister in a dry place.
Removing Lubrication Canister
1. Unplug cable from lubricator (FIG. 9).
Installing New Lubrication Canister
1. If a different size lubrication canister or discharge period is going to be used, change
dip switches to reflect the new canister size
and/or time change. See Table 1, page 13.
2. Place drive unit on top of new lubrication
canister until the teeth of both pieces are
locked.
3. Screw the cover of the drive unit onto the
lubrication canister - hand tighten only.
4. Remove plug (A) from bottom of lubrication canister.
FIG. 9
2. To disconnect adapter from lubrication
point, follow pressure relief procedure
provided on page 9.
3. Unscrew and completely
remove adapter (B) from
lubricator. Adapter will be
reused.
4. Unscrew cover from drive
unit.
5. Remove drive unit from the lubrication control.
5. Install lubricator unit into
adapter (B).
6. Screw lubricator into the lubrication point hand tighten only
second time.
Never screw in the lubricator a second time
or the self-sealing threads will be damaged.
7. For oil filled lubricators, make sure the
lubricator is installed vertically (outlet pointing down).
. DO NOT screw it in a
NOTICE
203A0417D
8. Plug cable back into lubricator (FIG. 10).
FIG. 10
9. The control time will start with the corresponding pause time.
Changing the Lubrication Canister
Lubrication Canister Disposal
Dispose of hazardous fluid in approved containers, and according to applicable guidelines. Read the MSDS to know the specific
hazards of the fluids you are using.
Storage
When lubricators are not immediately installed,
they must be stored in a dry, dust free, sunlight
protected room, indoors.
3A0417D21
Troubleshooting
Troubleshooting
MalfunctionPossible CauseSolution
Wrong cable connection
Connect cable according to pin
assignment (page 6). Check pin
assignment.
Lubricator does not function
Lubricator signals “system functions OK” (green LED), although
lubrication canister is empty
Cable ConstructionCable is drag chain qualified, approved for the
smallest bending radius 60 mm.
Conductor cross-section dimensions
Power Supply15 - 25 VDC (max 30 VDC) for at least 2 minutes
Temperature range-10°C to +50 °C (+14°F to +122°F)
Maximum output pressure5 bar (75 psi)
Storage
ConditionsDry, dust free
Temperature+20°C ± 5°C (+68°F ± 9°F)
Air born Noise Emission<70 dB(A)†
4 x 0.25 mm
Loctite® is a registered trademark of the Loctite Corporation.
† Emission sound pressure level of the lubrication system measured at distance of 1 m / height
1.6 m.
2
243A0417D
Discharge Amount per Cycle
Drive
Lubrication
Canister
1/4 npt
L
D
Technical Data
Discharge
Period
Pause
Time
Monthsh:min
11:30
34:37
69:17
1218:36
Weights and Measurements
TypeVolumeDiameter (D)
3
cm
EM-60602.03712.81425.600.3100.68
EM-1201204.06712.81656.500.3200.7
EM-2502508.45712.82158.460.3600.79
fl. ozmmin.mmin.kglbs
Discharge Amount per Discharge Cycle
EM-60EM-120EM-250
cm
3
fl. oz.
0.130.0040.260.0080.530.17
cm
3
fl oz.
cm
3
fl. oz.
Length (L)Weight (empty)
3A0417D25
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs
will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT
LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6928 or Toll Free: 1-800-533-9655, Fax: 612-378-3590
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
For patent information, see www.graco.com/patents.
Original instructions. This manual contains English. MM 3A0417
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 2010, Graco Inc. is registered to ISO 9001
www.graco.com
2010, revised December 2014
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