GCI Series Injectors

Yes, GCI Series injectors have similar firing and reset pressures as current injector technologies. This allows a customer to install GCI Series injector manifolds in conjunction with existing injectors on the same machine without having to change pump pressure settings. The mounting pattern of the GCI Series manifolds matches the mounting patterns of the same size -1, -1X or -V injector banks in the field. If multiple injector banks are hard plumbed together with pipe fittings, some of the mounting locations may need to be modified as the GCI Series manifolds are slightly wider than the current -1, -1X or -V injectors in the field.

The GCI Series injectors are designed to dispense grease at 2,000 psi and reset at 1,000 psi, which are the same operating pressures as our GL-1 X injectors. It is important to note that the system pressure needs to be set at a pressure that guarantees that the furthest injector bank sees over 2,000 psi. This helps ensure that the furthest lube points from the pump can dispense grease. Depending on the main line length and diameter, the pump pressure setting is typically between 2,500 and 3,000 psi if measuring pressure close to the pump.

GCI Series injector manifolds are available in two materials. The black anodized aluminum manifolds are lightweight, easy to install and are rated for systems up to 3,500 psi. This covers the vast majority of yellow iron and light industrial applications. We also offer zinc-plated steel manifolds for high pressure applications rated to 5,000 psi. The applications that typically require the higher-pressure manifolds are really large mining equipment, frac rigs or long lube line installations in factories that need a higher-pressure pump to ensure the injector manifolds furthest from the pump see at least 2,000 psi. Both sets of manifolds use the same GCI Series 150 cartridge and output spacers.

The GCI Series injectors will dispense between 0.015 and 0.150 cubic inches of grease per lubrication cycle, which is determined by the color-coded output spacer on the manifold for each point. This provides a 10X ratio for dialing in the grease amounts to various points of a machine and the highest GCI output is double the output of existing -1, -1X and -V injector technologies. Having double the output reduces the need to cross-port multiple injectors together, which lowers the total injector count needed to adequately grease a piece of equipment. The GCI Series injectors can also be cross ported to provide even more grease to a lube point. Cross porting two GCI Series injectors with the maximum output spacer (blue) is the same output as the –XL injectors and GCI Series injectors ported together is almost the same output of the much larger -11 injectors. Now an entire fleet of equipment can standardize on one injector platform and only have to worry about training their technicians how to service and troubleshoot that single platform.

GCI Series injectors are designed to be used with grease only, up to NLGI #2.

The GCI Series injectors are designed to function in extreme environments, from the hottest temperatures in Death Valley to some of the coldest climates on Earth. Special design considerations were taken to ensure the grease output does not vary simply due to external temperatures. Current -1, -1X or -V injector technologies lose output volume as temperature decreases, which results in roughly half of the desired lube amount going to critical lube points in the dead of winter at -40 ⁰F (-40 C) for each lube cycle. Today, customers are required to change the lubrication intervals to maintain proper greasing throughout the year. With the GCI Series injector technology, the output to the lube points is virtually unchanged whether the temperature is +120 ⁰F (49 C) or -40 ⁰F (-40 C), ensuring proper lubrication year-round. It is important to note that the grease also needs to be rated to the desired temperatures AND pumpable at those temperatures. Grease could be rated for -40 ⁰F (-40 C) but if it is close to solid at that temperature then it is not pumpable at -40 ⁰F (-40 C).

Injector technology has remained virtually the same for eight decades with multiple brands claiming to have a superior injector that from the outside looks and feels very similar to the next brand. Graco took a step back and re-engineered the decades-old design with simplicity in mind. The standard pressure (3,500 psi) aluminum GCI manifolds provides significant weight savings, and a more compact design makes it easier to mount injectors in tough-to-reach places. Having lube point outlets on two different planes of the manifold allows for greater flexibility for hose routing for a cleaner and more protected installation. The GCI Series injectors have double the grease output of the current -1, -1X or -V injectors, providing a greater available output ratio between lube points and reducing the need to cross-port multiple injectors together on high-use points. One of the greatest advantages comes when the injector needs to be replaced after lasting twice as long as other injectors in its class. Changing out the injector cartridge takes seconds! Without the need to remove pesky lube lines and adjacent injectors, GCI saves time to get your machine back up and running as quickly as possible and your technicians on to battling the next task sooner.

When you notice a lubrication point getting either too much or too little grease the first step in troubleshooting is to run a lubrication cycle and monitor the individual cartridge injector indicator pins. The indicator pins have a high-visibility blue anodized finish that is easy to see from any angle. All indicator pins should increase in height throughout the lubrication cycle. Each indicator pin has a machined grove, that once visible, lets you know that the injector has seen enough grease supply pressure for the internal valve to shift. If you notice one of the injector indicator pins fails to move during the lubrication cycle, then it is time to change that injector. A worn injector will typically result in grease bypassing through the injector. When that happens, it typically means too much grease will be going to that lubrication point and you will notice significant grease build-up on that point of the machine. As that injector continues to wear, there may be a period of time where downstream injectors do not see enough system pressure in the main line to fire those downstream injectors, resulting in those lubrication points not getting grease. Once you find the injector that is in bypass, you can replace that injector and then run subsequent lubrication cycles to ensure the rest of the injectors are firing properly.

Another place to look for signs of wear would be the small vent holes on the manifold. It is normal for a small amount of grease to appear at the vent hole. If a significant amount of grease is present or oozes from the vent hole during a lube event, that indicates a failed dynamic seal in the cartridge, and it is time to replace that cartridge. That failure mode is less common.

Another common lubrication issue is a lube point not taking grease. If you have one point on the machine that seems dry or is making noise that was not present before and all other points seem to be functioning normally, then start by removing the lubrication line from the GCI Series manifold and run a lubrication cycle. If no grease is dispensed and the groove on the indicator pin is visible, then change the GCI cartridge. If the indicator pin moves but does not rise to the point that the groove is visible, you can try increasing the pump pressure setting by a couple hundred psi (not exceeding the maximum pressure rating of the pump) and try another lubrication cycle. If grease is dispensed from the manifold and the lube point is dry, then there is likely a blocked or broken line between the GCI Series manifold and the lubrication point. Remove the lubrication line from the lube point and run a cycle. If grease dispenses from the lubrication line, then the lube point itself is either not taking grease or a higher output GCI Series output spacer needs to be installed on the GCI manifold to increase the amount of grease dispensed per cycle. For additional assistance please contact your Graco distributor or Graco LED Tech Assistance at LEDtech@graco.com or 1-800-533-9655 option 2.

Grease output per lubrication cycle on the GCI Series injector platform is dictated by the color-coded output spacer on the GCI manifold. To change the output spacer, simply remove the GCI Series injector cartridge with a 15/16 or 24mm 6-point socket. Set the injector in a clean location to be reinstalled shortly. Then use the same socket to remove the output spacer. Take the new desired output spacer size and ensure there is a small amount of non-permanent thread lock on the outer threads of the output spacer and then reinstall the new spacer onto the manifold. Please follow the torque specs listed in the GCI Series manual (Graco part number 3A9293). Once the spacer is torqued to the proper specification, you can reinstall the GCI Series injector cartridge and torque the cartridge to the specification listed in the manual. This process is shown in a how-to video on YouTube.

GCI Series injector banks are not assembled at Graco due to the seemingly endless output spacer combinations available for each manifold size. Distributors are able to order the proper GCI Series manifold size and material option, the GCI 150 injector cartridges and the corresponding output spacers to fit your specific application and lubrication requirements.