Graco 29:1 Lube Pro User manual

3A4096F
EN
Instructions
29:1 Lube Pro™
Vertical Grease
Pump
For pumping non-corrosive and non-abrasive grease only. For professional use only.
Not approved for use in explosive atmospheres or hazardous locations.
Models:
See page 2 for model information, including maximum working
pressure and approvals.
3500psi (24 MPa, 241 bar) Maximum Working Pressure
175 psi (1.2 MPa, 12.07 bar) Maximum Air Input
Pressure
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.

Models
2 3A4096F
Models
Part No. Size Low Level
Normally
Open
Normally
Closed EU
24Z051 1 lb
24Z052 1 lb X X
24Z053 1 lb X X
24Z054 1 lb X
24Z055 1 lb X X X
24Z056 1 lb X X X
24Z057 4 lb
24Z058 4 lb X X
24Z059 4 lb X X
24Z060 4 lb X
24Z061 4 lb X X X
24Z062 4 lb X X X

Warnings
3A4096F 3
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 or on warning labels, refer back to these Warnings. Product-spe-
cific 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
treatment.
• 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.
PRESSURIZED EQUIPMENT HAZARD
Over-pressurization can result in equipment rupture and serious injury.
• Do not exceed the maximum air input pressure.
• Fill slowly to avoid over pressurizing reservoir.
• Use tubing, hoses and other components with pressure ratings equal to or higher than the pump
rating.
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
or installing 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.

Warnings
4 3A4096F
PLASTIC PARTS CLEANING SOLVENT HAZARD
Many solvents can degrade plastic parts and cause them to fail, which could cause serious injury or
property damage.
• Use only compatible water-based solvents to clean plastic structural or pressure-containing parts.
• See Technical Data in this and all other equipment instruction manuals. Read fluid and solvent
manufacturer’s Safety Data Sheets (SDSs) and recommendations.
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 or installing 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.
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 SDS 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 manu-
facturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and cre-
ate 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.
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 SDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equip-
ment, follow the Pressure Relief Procedure and disconnect all power sources.
WARNING

Warnings
3A4096F 5
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. Protective equipment includes but is not
limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent 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.
WARNING

Installation
6 3A4096F
Installation
Typical Installation
Key:
A Main Air Supply Line
B Filter/Regulator/Lubricator Assembly
B1 - Air Filter
B2 - Air Regulator
B3 - Air Lubricator
C Air solenoid valve (3-way)
D Pump module
E Pump outlet
F Bleed-type master air valve (required)
G High pressure lubricant supply lines (user supplied)
H Injector
J Lubricator controller
K Pump reservoir
L Pump reservoir fill port
M Ground
P Pump air inlet - forward stroke
R Air outlet
S Feeder lines
T Low level
U Air supply lines
FIG. 1: Typical Installation
J
A
B1 B3
B2
C
U
F
E
K
U
R
D
P
M
T
G
H
S
L

Installation
3A4096F 7
Grounding
To ground the pump (FIG. 2):
1. Remove the ground screw (Z) located on the back
of the pump base.
2. Insert the ground screw (Z) through the eye of the
ring terminal (W) located at the end of the ground
wire (Y).
3. Fasten the ground screw (Z) back onto the back of
the pump and tighten the screw securely.
4. Connect the other end of the ground wire (Y) to a
true earth ground.
Mounting
Install the pump in a location that will adequately sup-
port the weight of the pump when it is filled with lubri-
cant and also provides easy operator access to the
pump air controls. The pump must be mounted in a ver-
tical position with the reservoir up. See Technical Data,
page 29 for pump weight information and the Dimen-
sions, page 28.
Low Level Models Only
DIN Connector
Connection o s made to PINS 1 and 3 of the DIN Field
Wire-able Connector. See FIG. 3.
Grounding is necessary when voltages above 30
VAC or 42 VDC are used for the low level switch or an
air valve is attached to the pump. Improper ground-
ing can cause electric shock. Grounding reduces the
risk of electric shock by providing an escape wire for
the electric current in the event of malfunction or
breakdown.
FIG. 2
Mount the pump securely so that it cannot move
around during operation. Failure to do so could result
in injury or equipment damage.
FIG. 3

Installation
8 3A4096F
Air and Fluid Line Accessories
Refer to FIG. 1, page 6, for the following instruction
Install the air line accessories in the order shown in FIG.
1, page 6.
Bleed-type master air valve (F): required in your sys-
tem to relieve air trapped between it and the pump.
Air line filter (B1): removes harmful dirt and moisture
from compressed air supply.
Pump air regulator (B2): to control pump speed and
outlet pressure. Locate it close to the pump.
1. Install a bleed-type master air valve (F) to relieve air
trapped between it and the pump. Install the valve
in a location that is easily accessible from the pump
and located downstream of the air regulator.
2. Install an air line filter (B1) to remove harmful dirt
and contaminants from the compressed air supply.
3. Install the air regulator (B2) to control pressure.
4. Install an air line lubricator (B3) to lubricate the air
cylinder.
5. Install the (3-way) air solenoid valve (C) for control
of the pump forward and return strokes.
To use the air regulator reading to determine the fluid
output pressure, multiply the ratio of the pump (29:1)
by the air pressure shown on the regulator gauge or
see Table 1: Lubricant Output - PSI or Table 2: Lubri-
cant Output - MPa (bar), provided on page 13.
Limit the air to the pump so that no air line or fluid line
component or accessory is over pressurized.
Air Supply Lines (U)
1. Install two air supply lines (U) between the air sole-
noid outlets (C) and the pump (D) as shown in the
Typical Installation, page 6.
2. Install an air supply line (U) between the air solenoid
valve inlet (C) and the Filter/Regulator/Lubricator
Assembly (B) as shown in the Typical Installation,
page 6.
Fill Reservoir
1. Remove the grease cap (43) (FIG. 4) from the fill port
to access the fill stud (42).
2. Connect the quick connect fitting on the fill pump
to the fill port (42).
Trapped air can cause the pump to cycle unexpect-
edly which could result in serious injury from moving
parts or splashing.
NOTICE
Do not mount the air accessories directly on the
solenoid valve air inlet. The air inlet and fittings are
not strong enough to support the accessories and
may break. Provide a bracket on which to mount the
accessories.
The maximum working pressure of each
component in the system may not be the same.
To reduce the risk of over-pressurizing any part of
your system, know the maximum working
pressure rating of each component and its
connected components. Never exceed the
maximum working pressure of the lowest rated
components connected to a particular pump.
FIG. 4
Over-pressurization can result in equipment
rupture and serious injury. Fill slowly to avoid over
pressurizing the reservoir.
42
43

Installation
3A4096F 9
3. Slowly dispense grease from the fill pump into the
reservoir until the grease in the reservoir lifts the fol-
lower plate (22) above the reservoir weep hole (wh),
grease comes out of the weep hole (wh) and expels
the air inside the reservoir (FIG. 5).
4. Disconnect the fill pump from the fill stud (42) (FIG.
4, page 8).
5. Secure grease cap (43) over the fill stud (42) (FIG. 4,
page 8).
Priming
Refer to FIG. 1, page 6, for the following instruction
NOTE:
• Prime the pump before connecting the outlet to
supply line (G).
• Before priming the pump, the reservoir must be
filled with lubricant (see Fill Reservoir instructions,
page 8).
Run the pump until grease (gr), free of air, comes out of
the pump outlet (E). See Operation, page 12.
• It may take up to 20 the pump strokes to prime the
pump. This will depend on the viscosity of the lubri-
cant and temperature.
• Allow 5 seconds ON time for the forward stroke and
5 seconds OFF time for the return stroke.
Supply Lines (G)
Refer to FIG. 1, page 6, for the following instruction
1. Run the pump until grease (gr), free of air, comes
out of the pump outlet (E). Connect the supply line
(G) to the pump outlet (E).
2. If there are multiple pumps on the air line, close the
air regulators and bleed-type master air valves to all
but one the pumps. If there is only one pump, open
its air regulator and bleed-type master air valve.
3. Open the master air valve from the compressor.
4. Set the air pressure to each pump at the lowest
pressure needed to get the desired results. See
Recommended Pressure provided in Table 1:
Lubricant Output and Pressure - US or Table 2:
Lubricant Output and Pressure - Metric provided
on page 13.
Feeder Lines (S)
Fill each feeder line (S) with lubricant prior to connect-
ing lines to the injector outlet.
Injectors
1. Check each injector for proper operation. The injec-
tor stem should move when lubricant is discharged.
2. Adjust the injector output if needed to ensure that
the output volume discharged is sufficient.
FIG. 5
22
(wh)
(gr)

Installation
10 3A4096F
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
1. Close the bleed-type master air valve (F, page 6)
(required in the system).
2. Relieve pressure in system using two wrenches
working in opposite directions on the pump outlet
(E) and lubrication line fitting (G) to slowly loosen
the fitting until it is loose and no more lubricant or
air is leaking out of the fitting (FIG. 6).
Air Lock Procedure
The reference letters used in the following instructions
refer to the Typical Installation FIG. 1 on page 6.
An air lock occurs when a bubble or pocket of air pre-
vents the normal flow of the lubricant.
If there is an air lock:
1. Refill the reservoir to the full level (page 8).
2. Relieve pressure. See Pressure Relief Procedure,
page 10.
3. Disconnect the lubricant supply line (G) from the
pump outlet (E) (FIG. 7).
4. Open the bleed-type master air valve (F, page 6).
5. Run the pump a few strokes until grease, free of air,
comes out of the pump outlet (E) (FIG. 7).
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 dispensing and before
cleaning, checking, or servicing the equipment.
FIG. 6
E
G
NOTICE
Running the pump dry will cause an air lock. To pre-
vent an air lock, do not run the pump without lubricant.
Always refill the pump before it is empty.
FIG. 7
E
G

Installation
3A4096F 11
• It may take up to 20 the pump strokes to expel the
air from the pump and deliver a continuous flow of
grease. This will depend on the viscosity of the
lubricant and temperature.
• Allow a minimum of 5 seconds ON time for the for-
ward stroke and 5 seconds OFF time for the return
stroke.
6. Connect the pump outlet (E) to the lubrication line
(G) (FIG. 8).
FIG. 8
E
G

Operation
12 3A4096F
Operation
Pump
Start Up
1. Verify reservoir is filled with lubricant and system
has been primed (see Prime System, page 9).
2. Turn on the lubrication controller (J) power switch.
3. Program the lubrication controller to actuate the
solenoid valve (C).
NOTE: See the lubrication controller instruction
manual included with the system for these instruc-
tions.
4. Open air regulators and master air valves.
NOTE: Never allow the pump to run dry of the material
being the pumped.
At the start of a the pump cycle:
a. The air solenoid (C) supplies air to the pump air
inlet (P).
b. On the pump forward stroke, lubricant is dis-
pensed to all the injectors.
c. The pump is supplied with air through the air
inlet (R).
d. The pump makes a return stroke, venting the
system pressure back to the pump and reset-
ting all of the injector.
Low Level Switch
As grease is dispensed, the follower plate (22) travels
down the reservoir. When it gets close to the low level
switch (lls) the magnet (28) on the bottom of the fol-
lower plate assembly activates the normally closed low
level switch; opening the switch and sending a signal to
the lubricator controller (J) (FIG. 9).
Shut Down
To shut down the system:
a. Close the bleed-type master air valve (F, page
6).
b. Turn off electrical supply to the lubrication con-
troller (J, page 6).
NOTICE
Running the pump dry will cause an air lock. To pre-
vent an air lock, do not run the pump without lubricant.
Always refill the pump before it is empty. FIG. 9
llf
(lls)
(28)
(22)

Operation
3A4096F 13
Lubrication System Sizing and Calculation Guidelines
Table 1: Lubricant Output and Pressure - US
NOTE: The lubricant output per pump stroke must be less than the amount of lubricant discharged per pump
stroke.
Table 2: Lubricant Output and Pressure - Metric
1. Total Injector Volume to Dispense and Charge
a. Add together the total number of injectors in the sys-
tem.
b. From Table 1 or Table 2 above, find your Injector
Type in the first column and the related Injector Vol-
ume to Charge in the third column. Multiply this
value by the total number of injectors determined in
Step a (above).
2. Calculate the volume of lubricant in the pipeline (G):
a. Use the pipe’s inside diameter (ID) measurement to
calculate the area of the pipe.
b. Measure the length of the pipe (G) only. Do not
include the feeder lines (S) in this calculation.
c. Multiply the area of the pipe (calculated in Step a) by
the length of the pipe (measured in Step b).
3. Calculate line expansion and fluid compression in the
pipe using the 10% Rule.
a. Multiply the volume calculated in Step 2 by 10%.
4. Calculate the Total System Volume required.
a. Add together the total from Step 1 and Step 3 ONLY.
Do NOT include Step 2.
b. The Total System Volume required must be less than
the Pump Lubricant Output / Stroke provided in the
fourth column of Table 1 or Table 2.
c. If the Total System Volume required is greater than
the Pump Lubricant Output / Stroke provided in the
fourth column of Table 1 or Table 2, split the system
into two or more systems.
1 2 3 4 5 6 7
Injector
Type
Max
Injector
Output
cu. in.
Injector
Volume to
Dispense
and Charge
cu. in.
Max Pump
Lubricant
Output /
Stroke
cu. in.
Minimum Pressure Maximum
Pressure Recommended Pressure
Output PSI
Required Air
PSI Output PSI
Required
Air PSI Output PSI
Required Air
PSI
GL-1 0.080 0.011
0.58
1850 66
3500 120
2500 86
GL-32 0.008 0.016 1200 46 1500 58
GL-33 0.003 0.006
1 2 3 4 5 6 7
Injector
Type
Max
Injector
Output
cc
Injector
Volume to
Dispense
and
Charge
cc
Max Pump
Lubricant
Output /
Stroke
cc
Minimum Pressure Maximum
Pressure Recommended Pressure
Output
MPA (bar)
Required Air
MPA (bar)
Output
MPA (bar)
Required Air
MPA (bar)
Output
MPA (bar)
Required Air
MPA (bar)
GL-1 1.13 2.26
9.5
12.7 (127.6) 0.45 (4.5)
24 (241.3) 0.83 (8.3)
17.2 (172.4) 0.59 (5.9)
GL-32 0.13 0.262 8.3 (82.7) 0.3 (3.2) 10.3 (103) 0.4 (4.0)
GL-33 0.049 0.098

Repair
14 3A4096F
Repair
Seal Replacement
NOTE: For most seal replacement procedures, the pump should be completely removed from service and clamped
in a vise. If you are only replacing the reservoir and/or reservoir seals, you do not have to remove the pump from its
service location. The following instructions cover the complete disassembly of the pump. Your pump repair may not
require total pump disassembly.
Disassembly
1. Turn off air supply and disconnect air lines to the
pump.
2. Disconnect electrical connections to lubrication
controller.
3. Relieve pressure (page 10).
4. Disconnect supply line (G, page 6) from the pump
outlet (E, page 6).
5. Remove fill cap (43). Then use a wrench to loosen
and slowly remove the fill stud (42). (FIG. 10).
NOTE: After fill stud is removed, the spring com-
pressing the follower plate will force the grease out
of the reservoir.
6. Collect drained grease in a pail or waste container.
Dispose of grease according to all regulations for
proper disposal.
7. Remove mounting bolts (FIG. 11) and remove the
pump from service.
FIG. 10
43
42
FIG. 11

Repair
3A4096F 15
8. Clamp the pump base in a vise as shown in FIG. 12.
Use a soft-jaw vise or place a rag in the vise jaws to
protect the surface of the pump base.
9. Reservoir Gaskets (10)
Cover (18) is spring loaded. Use your hand to apply
pressure on the cover. At the same time, use a
wrench to loosen and remove nut (17) from reser-
voir cover (18) (FIG. 13).
10. Remove cover (18) and spring (15) from reservoir
(11).
11. Remove reservoir (11) from the air motor cylinder
(3) (FIG. 14). If replacing reservoir gaskets (10),
remove gaskets from reservoir. Dispose of gaskets
according to all regulations for proper disposal.
FIG. 12
FIG. 13
17
18
FIG. 14
11
10
18
17
3
15
ti28818

Repair
16 3A4096F
12. Outlet Tube O-Ring (13) and Pump Cylinder
O-Ring (9)
Securely hold nut (3a) [located on the bottom of the
pump cylinder (12)] in place with a wrench. Secure
a second wrench on the flats of the outlet tube (14).
Turn outlet tube counter-clockwise to loosen and
remove it from the pump cylinder (12) (FIG. 15).
13. Loosen nut (3a) and remove pump cylinder (12)
from air motor cylinder (3) (FIG. 16).
14. Remove o-ring (13) from outlet tube (14). Remove
o-ring (9) from pump cylinder (12). Dispose of
o-rings according to all regulations for proper dis-
posal (FIG. 17).
FIG. 15
FIG. 16
14
12
3a
flats
3a
12
3
FIG. 17
12
9
13
14
19

Repair
3A4096F 17
15. Pump Piston Subassembly (33)
Secure a wrench on the flats of piston rod (34). Use
a second wrench to remove lock nut (31) and star
washer (32) from top of piston (FIG. 18). Remove
lock nut and star washer. Keep these parts for reas-
sembly.
16. Examine the piston assembly (33) for scratches and
other wear and damage. If damaged, replace the
pump piston assembly (33).
17. Reposition air motor cylinder in vise to access the
bottom of air motor cylinder (FIG. 19).
18. Secure a wrench on the cover nut (1a). Turn it
counter-clockwise loosen and remove the cover (1)
from bottom or air motor cylinder. (FIG. 19).
NOTE: There is a spring (6) (FIG. 20) inside the air
motor cylinder (3) under the piston (5). Hold your
hand on the cover (1) for resistance and to hold it
down while loosening the cover screws (1a) (FIG.
20).
FIG. 18
33
32
31
31
32
34
33
FIG. 19
FIG. 20
1A 1
5
6
3
34

Repair
18 3A4096F
19. Remove cover (1), cover o-ring (2) and spring (6).
Dispose o-ring according to all regulations for
proper disposal (FIG. 21).
20. Piston Rod O-Ring (36) and Piston Seal (4)
a. Remove piston rod (34) and piston (5). and
spring (6) from air motor cylinder (3) (FIG. 20).
b. Separate piston rod (34) and piston (5) using
two wrenches, working in opposite directions.
Secure one wrench to flats of piston rod and
the second wrench to loosen the nut (37) (FIG.
22).
c. Remove o-ring (4) from piston (5) (FIG. 23).
d. Dispose of piston seal (4) and o-ring (34a) and
nut (37) according to all regulations for proper
disposal.
21. Use a pick to remove o-ring (34a) from piston rod
(34) (FIG. 24).
FIG. 21
FIG. 22
1
2
3
34
37
5
FIG. 23
FIG. 24
5
4
34
34a

Repair
3A4096F 19
22. Use a pick to remove the bushing (35) and u-cup
seal (36) (FIG. 25).
23. Use a smooth, long brass or aluminum rod, free of
sharp edges and burrs, to push the check valve
assembly (19) out of the outlet tube (14) (FIG. 26).
24. Dispose of the check valve assembly (19) accord-
ing to all regulations for proper disposal.
FIG. 25
FIG. 26
35
36
19 14

Repair
20 3A4096F
Reassembly
Use all new part included in the repair / service kit even
if the old parts do not appear to be worn or damaged
and dispose of old parts according to all regulations for
proper disposal.
1. Install u-cup seal (36) with lips facing up, and bush-
ing (35) in air cylinder (3) (FIG. 27).
2. Check Valve Assembly (19)
Coat the new check valve assembly (19) with a thin
layer of grease.
3. Use a smooth, long brass or aluminum rod, free of
sharp edges and burrs, to push the check valve
assembly (19) into place in the outlet tube (14) (FIG.
28).
4. Piston Rod O-Ring (34a) and Piston Seal (4)
NOTE: Do not clamp piston rod (34) in vise.
Use a clean cloth to wipe down the piston rod (34)
and piston (5) and remove any dirt or contaminants.
Inspect surfaces for any scratches or damage.
Replace damaged parts.
5. Apply a thin layer of grease to o-ring (34a). Install
o-ring over the grooves of piston rod (34) (FIG. 29).
NOTE: If needed, a pick can be used to help seat
the o-ring over the grooves of the piston rod (13).
6. Push piston (5) over end of piston rod (34) until it is
seated on the rod (FIG. 30).
NOTE: You should hear a pop sound when it is in
place correctly.
FIG. 27
FIG. 28
36 35
19
14
FIG. 29
FIG. 30
34
34a
5
34