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

Installation
332316E 11
FIG. 3
(4)
(2)
(1)
1
2
3
4
Example Wiring Diagram
Connector on Housing
Connector on Cable
(4)
(1)
(3)
(2)

Installation
12 332316E
Power DIN DC- 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. 4, page 13)
NOTICE
Be sure when power is applied that stirring paddle
rotates clockwise (when viewed from the top). If it is
wired incorrectly paddle could rotate counter-clockwise
which will damage the pump’s internal components. If
this happens, stop the pump immediately and wire unit
correctly.
UnitedStates/
Canada Europe Japan/Taiwan SEA/India/
Australia China
1‐VDC Black Brown Black Brown Brown
2 +VDC White Blue White Blue Blue
3NotUsed NotUsed NotUsed NotUsed NotUsed NotUsed
4NotUsed Green Green/Yellow Red Green/Yellow Green/Yellow
Pin PinName
Color

Installation
332316E 13
FIG. 4
Ignition Switch
Fuse
1
2
3
4
Example Wiring Diagram
Connector on Housing
12V-pump - 7.5A - Graco kit #571039
24V pump - 4A - Graco kit #571040
(4)
(2)
(1)
Connector on Cable
(4)
(1)
(3)
(2)

Installation
14 332316E
Power CPC DC- 15 foot: Part No. 127783
CPC Connector Specifications
• One, 7-position, 1.5 mm socket connector AMP 967650-1
• Three, 16 - 14 gauge female pins AMP 962999-1
• One, 180-degree strain relief or one, 90-degree strain relief AMP 965576-1 (determined by cable exit for cable
configuration)
Installation Notes
• Crimp pins to wire and install in socket connector per manufacturer’s instructions.
• See Pin Layout shown in FIG. 5 for proper location in the connector.
• Secure socket connector to the cable per the desired strain relief configuration.
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. 5, page 15)
UnitedStates/
Canada Europe Japan/Taiwan SEA/India/ Australia China
1NotUsed NotUsed NotUsed NotUsed NotUsed NotUsed
2‐VDC Black Brown Black Brown Brown
3 +VDC White Blue White Blue Blue
4NotUsed NotUsed NotUsed NotUsed NotUsed NotUsed
5NotUsed NotUsed NotUsed NotUsed NotUsed NotUsed
6NotUsed NotUsed NotUsed NotUsed NotUsed NotUsed
7NotUsed Green Green/Yellow Red Green/Yellow Green/Yellow
Pin PinName
Color

Installation
332316E 15
FIG. 5
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Example Wiring Diagram
Connector on Housing Connector on Cable
Ignition Switch
Fuse
1
2
3
4
5
6
7
12V-pump - 7.5A - Graco kit #571039
24V pump - 4A - Graco kit #571040
(1)
(3)
(2)
(7)
(6) (5)
(4)

Installation
16 332316E
Part No. 124333:
Cable Pin Out (M12) (FIG. 6)
Wire Colors
Part No. 124300:
Field Wireable Pin Out (M12) (FIG. 7)
Wire Colors
Item No. Color
1Brown
2White
3Blue
4Black
FIG. 6











Item No. Color
1Brown
2White
3Blue
4Black
FIG. 7







Installation
332316E 17
Part No. 124594:
4 Pin Eurofast Field Wireable Connector
(FIG. 8)
Part No. 124595:
5 Pin Eurofast Field Wireable Connector
(FIG. 9)
FIG. 8




FIG. 9






Setup
18 332316E
Setup
Pressure Relief
Follow the Pressure Relief Procedure when-
ever you see this symbol.
Relieve pressure in system using two wrenches work-
ing in opposite directions on pump element and pump
element fitting to slowly loosen fitting only until fitting
is loose and no more lubricant or air is leaking from fit-
ting.
NOTE: When loosening pump element fitting, do NOT
loosen pump element. Loosening pump element will
change the output volume.
Connecting to Auxiliary Fittings
Pressure Relief Valves
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 spraying
and before cleaning, checking, or servicing the
equipment.
FIG. 10
NOTICE
Do not attach unsupported equipment to auxiliary fit-
tings such as fill ports and pump element. Attaching
unsupported equipment to these fitting can result in
irreparable housing damage.
• Always use two wrenches working in opposite
directions when connecting anything to pump ele-
ment or auxiliary fittings. See FIG. 10 for an exam-
ple.
• Torque pump element fittings to 50 in. lbs (5.6
N•m).
• When connecting pump element into housing
torque to 50 in. lbs (5.6 N•m).
A pressure relief valve appropriate for the lubrication
system must be installed close to the pump outlet to
alleviate unintended pressure rises in the system and
protect the G1 pump from damage.
• Only use a pressure relief valve that is rated for no
more than the working pressure of the G1 pump it
is installed on. See Technical Data, page 29.
• Install a pressure relief valve before any auxiliary
fitting.

Setup
332316E 19
Loading Grease
To ensure optimal performance from the G1:
• Only use NLGI #000 - #2 greases appropriate for
your application, automatic dispensing, and the
equipment’s operating temperature. Consult with
machine and lube manufacturer for details.
• The reservoir can be filled using a hand operated
pump, pneumatic pump or electric transfer pump.
• Do not overfill (FIG. 12).
• Do not operate G1 without reservoir attached.
Models without a follower plate:
1. Connect fill hose to inlet fitting *(37) (FIG. 11).
2. For higher viscosity fluids, start pump per your con-
troller specifications, to rotate stirring paddle during
fill to prevent air pockets from forming in grease.
3. Fill reservoir with NLGI grease to max fill line.
NOTE: Vent port, located in rear of reservoir, should not
be used as an overfill port/indicator.
4. Remove fill hose.
Models with a follower plate:
1. Connect fill hose to inlet fitting (FIG. 11).
2. For higher viscosity fluids, start pump per your con-
troller specifications, to rotate stirring paddle during
fill to prevent air pockets from forming in grease.
3. Fill reservoir with grease until seal of follower plate
breaches the vent hole (FIG. 13) and the majority of
air is expelled from the reservoir.
NOTE: Vent port, located in rear of reservoir, should not
be used as an overfill port/indicator.
4. Remove fill hose.
Changing Greases
When changing greases, always use compatible fluids
or greases.
NOTICE
• Always clean fitting (37) with a clean dry cloth
prior to filling reservoir. Dirt and/or debris can
damage pump and/or lubrication system.
• Care must be used when filling the reservoir
using a pneumatic or electric transfer pump to
not pressurize and break the reservoir.
FIG. 11
37
FIG. 12
FIG. 13
max fill line
vent hole

Setup
20 332316E
Filling Oil Unit
• Only use oil appropriate for your application, auto-
matic dispensing, and the equipment’s operating
temperature. Consult with machine and lube manu-
facturer for details.
• The reservoir can be filled using a hand operated
pump, pneumatic pump or electric transfer pump.
• Do not overfill (FIG. 14).
• Do not operate G1 without reservoir attached.
• Only use oils with viscosity at least 40 cSt.
1. Remove fill cap (a).
2. Pour oil into reservoir to fill line (b).
3. Replace fill cap. Hand tighten cap, securely.
Priming
NOTE: It is not necessary to prime pump every time
pump is filled with lubricant.
Pump only requires priming the first time it is used or if it
is allowed to run dry.
1. Loosen pump element fitting (FIG. 15).
NOTE: When loosening pump element fitting, do NOT
loosen pump element. Loosening pump element will
change the output volume
2. Only run pump until air is no longer dispensed with
the lubricant coming out of element fitting (FIG. 16).
3. Tighten pump element fitting using two wrenches
working in opposite directions (FIG. 15).
FIG. 14
a
b
FIG. 15
FIG. 16