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.

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:

Oil Models

Grease Models

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

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

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

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