Graco G1 User manual

Instructions
G1™Standard
Lubrication Pump 332316E
For dispensing of NLGI Grades #000 to #2 greases and oil with at least 40cSt. For
Professional Use Only.
Not approved for use in explosive atmospheres or hazardous locations.
Part Nos., page 3
5100 psi (35.1 MPa, 351.6 bar) Maximum Working Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
EN
3132066
conforms to AN-
SI/UL 73
certified to
CAN/CSA
Std. 22.2 No 68-09

Table of Contents
2332316E
Table of Contents
Grease Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Oil Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component Identification . . . . . . . . . . . . . . . 6
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 7
Choosing an Installation Location . . . . . . . . . . . . 7
System Configuration and Wiring . . . . . . . . . . . . 8
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . . . 18
Connecting to Auxiliary Fittings . . . . . . . . . . . . . 18
Loading Grease . . . . . . . . . . . . . . . . . . . . . . . . 19
Filling Oil Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
No Controller Operation . . . . . . . . . . . . . . . . . . . . 21
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Parts Drawing: 2 Liter Models . . . . . . . . . . . . . . . 25
Parts Drawing: 4 and 8 Liter Models . . . . . . . . . . 26
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Pressure Relief Valves . . . . . . . . . . . . . . . . 28
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installation and Repair Kits . . . . . . . . . . . . . 28
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Mounting Pattern . . . . . . . . . . . . . . . . . . . . . . . . 30
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 32

Grease Models
332316E 3
Grease Models
Oil Models
Model Reservoir Size Voltage CPC DIN Wiper Follower Low
Level
2 Liter 4 Liter 8 Liter 12V DC 24V DC 100-240
VAC
94G006 X X X X
94G007 X X X X
94G008 X X X X
94G009 X X X X X
94G010 X X X X X
94G011 X X X X X
94G018 X X X X
94G019 X X X X
94G020 X X X X
94G021 X X X X X
94G022 X X X X X
94G023 X X X X X
94G036 X X X X
94G037 X X X X
94G038 X X X X
94G039 X X X X X
94G040 X X X X X
94G041 X X X X X
94G063 X X X X
94G064 X X X X
94G065 X X X X
94G066 X X X X X
94G067 X X X X X
94G068 X X X X X
94G069 X X X X X
94G070 X X X X X
94G071 X X X X X
Model Reservoir Size Voltage CPC DIN Low
Level
2 Liter 4 Liter 8 Liter 12V DC 24V DC 100-240
VAC
94G042 X X X
94G043 X X X
94G044 X X X
94G045 X X X X
94G046 X X X X
94G047 X X X X
94G072 X X X
94G073 X X X
94G074 X X X
94G075 X X X X
94G076 X X X X
94G077 X X X X

Warnings
4332316E
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-specific
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where
applicable.
WARNING
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 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 manufacturer’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.

Warnings
332316E 5
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.
•A pressure relief valve is required at each pump outlet.
Follow Pressure Relief Procedure in this manual before servicing.
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 MSDSs and recommendations.
MOVING PARTS HAZARD
Moving parts can pinch 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 equipment, follow the
Pressure Relief Procedure in this manual. Disconnect power or air supply.
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 solvent manufacturer.
WARNING

Installation
6332316E
Installation
Grounding
Component Identification
Key:
A Reservoir
B Pump Element
C Pressure Relief Valve (Not included / required)
D Zerk Inlet Fill Fitting (1 included / grease models only)
E Power, DIN (if equipped)
F Power, CPC (if equipped)
G Low Level Output (if equipped)
H Model Number/ Serial Number
J Follower Plate (grease models only / not available on all
grease models)
K Vent Hole
L Fill cap (oil models only)
The equipment must be grounded. Grounding reduces the risk
of electric shock by providing an escape wire for the electrical
current in the event of malfunction or breakdown.
FIG. 1:
A
D
H
J
Oil Models
L
Grease Models
E
C
K
B
F
G
Grease Models with Follower Plate

Installation
332316E 7
Typical Installation
A Connected to fuse / power
B Pressure relief valve (required, user supplied) C Series progressive divider valves D To lube points
Choosing an Installation Location
• Select a location that will adequately support
the weight of the G1 Pump and lubricant, as
well as all plumbing and electrical connections.
• Refer to the two mounting hole layouts provided
in the Mounting Pattern section of this manual,
page 30.
NOTE: The two mounting hole layouts provided
in the Technical Data section show the only cor-
rect installation patterns to use for mounting the
G1. No other installation configurations should
be used.
• Use designated mounting holes and provided
configurations only.
• Always mount the G1 oil models upright.
• If the G1 grease model is going to be operated
in a tilted or inverted position for any period of
time, you must use a model that includes a fol-
lower plate, otherwise the G1 must be mounted
upright.
• Use the three fasteners (included) to secure the
G1 to the mounting surface.
FIG. 2
A
B
D
C
AUTOMATIC SYSTEM ACTIVATION HAZARD
Unexpected activation of the system could result in serious injury, including skin injection and amputation.
This device has an automatic timer that activates the pump lubrication system when power is connected or when exit-
ing the programming function. Before you install or remove the lubrication pump from the system, disconnect and iso-
late all power supplies and relieve all pressure.

Installation
8332316E
System Configuration and Wiring
If the product is permanently connected:
• it must be installed by a qualified electrician or ser-
viceman.
• it must be connected to a grounded, permanent wir-
ing system.
If an attachment plug is required in the end use
application:
• it must be rated for the product electrical specifica-
tions.
• it must be an approved, 3-wire grounding type
attachment plug.
• it must be plugged into an outlet that is properly
installed and grounded in accordance with all local
codes and ordinances.
• when repair or replacement of the power cord or
plug is required, do not connect the grounding wire
to either flat blade terminal.
Fuses
Fuse Kits are available from Graco. The following Table
identifies the correct fuse to use for your input voltage
and the corresponding Graco Kit number.
Recommendations for Using Pump in
Harsh Environments
• Use pump with CPC style power cable.
• If using a DIN style power harness with a right angle
mating connector, make sure the connector does
not exit the unit in the UP direction.
• Use a corrosion preventative electrical grease on all
contacts.
.Improper installation of the grounding conductor may
result in a risk of electric shock. This product must be
installed by a qualified electrician in compliance with
all state and local codes and regulations.
NOTICE
Fuses (user supplied) are required on all DC models. To
avoid equipment damage:
• Never operate G1 Pump DC models without a fuse
installed.
• A fuse of the correct voltage must be installed in line
with the power entry to the system.
Input Voltage Fuse Value Graco Kit No.
12 VDC 7.5 A 571039
24 VDC 4 A 571040

Installation
332316E 9
Wiring and Installation Diagrams
NOTE: Graco does not provide a power cable with the G1. Power cables are available for purchase from Graco or the
user may provide their own. See Table 1 for reference pages containing additional information related to Graco power
cables.
Table 1: Graco Power Cables
Cable Part No. Diagram Symbol Page #
123358
DIN 15 ft.
Power DIN AC 10
Power DIN DC 12
127783
CPC 15 ft., 3-wire Power CPC DC 14
124333
5 meter
female to male
M12 Eurofast
Low Level Outputs
16
124300
5 meter
female M12 Eurofast 16
124594
4-pin
Eurofast Field-wireable 17
124595
5-pin female
Eurofast Field-wireable 17

Installation
10 332316E
Power DIN AC - 15 foot: Part No. 123358
Din Connector Specifications
• DIN 43650 Form A, 18 mm, assembled to power cable manufacturer’s instructions
• Rated to 6 Amps minimum at 250V AC
Cable Specifications
•United States/Canada: 3 conductor 16 AWG UL62 and CSA 22.2 No. 49 listed SOOW cable with black, white,
green insulation
•Europe: 3 Class-5 conductor, 1.5 mm2Agency Listed H07RN-F cable with blue, brown, green/yellow insulation
•Japan/Taiwan: 3 conductor, 1.25 mm2 Agency Listed 2 PNCT cable with black, white, red insulation
•SEA/India/Australia: 3 conductor, 1.5 mm2 Agency Listed H07RN-F blue, brown, green/yellow insulation
•China: 3 conductor, 1.5 mm2Agency Listed YZW cable with blue, brown, green/yellow insulation
Pin and Related Wire Color (FIG. 3, page 11)
UnitedStates/
Canada Europe Japan/Taiwan SEA/India/ Australia China
1 LINE Black Brown Black Brown Brown
2 NEUTRAL White Blue White Blue Blue
3NotUsed NotUsed NotUsed NotUsed NotUsed NotUsed
4 GROUND Green Green/Yellow Red Green/Yellow Green/Yellow
Color
Pin PinName