Instructions
3132066
conforms to
ANSI/UL 73
certified to
CAN/CSA
Std. 22.2 No 68-09
™
G1
Standard
332316C
Lubrication Pump
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
Table of Contents
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
2 332316C
Grease Models
Grease Models
Reservoir Size Voltage
Model
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
CPC DIN Wiper Follower
Low
Level
Oil Models
Reservoir Size Voltage
Model
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
332316C 3
CPC DIN
Low
Level
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation 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.
4 332316C
Warnings
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.
• 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.
332316C 5
Installation
A
D
H
J
Oil Models
L
Grease Models
E
C
K
B
F
G
Grease Models with Follower Plate
Installation
Grounding
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.
Component Identification
FIG. 1:
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)
6 332316C
Typical Installation
A
B
D
C
Installation
FIG. 2
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
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 exiting the programming function. Before you install or remove the lubrication pump from the system, disconnect and isolate all power supplies and relieve all pressure.
• 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 correct 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 follower plate, otherwise the G1 must be mounted
upright.
• Use the three fasteners (included) to secure the
G1 to the mounting surface.
332316C 7
Installation
System Configuration and Wiring
Fuses
.
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.
If the product is permanently connected:
• it must be installed by a qualified electrician or serviceman.
• it must be connected to a grounded, permanent wiring system.
If an attachment plug is required in the end use
application:
• it must be rated for the product electrical specifications.
• 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.
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.
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.
Input Voltage Fuse Value Graco Kit No.
12 VDC
24 VDC 4 A 571040
7.5 A
571039
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.
8 332316C
Installation
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 #
Power DIN AC 10
123358
DIN 15 ft.
Power DIN DC 12
126217
CPC 15 ft., 3-wire
124333
5 meter
female to male
M12 Eurofast
124300
5 meter
female M12 Eurofast
124594
4-pin
Eurofast Field-wireable
124595
5-pin female
Eurofast Field-wireable
Power CPC DC 14
16
16
Low Level Outputs
17
17
332316C 9
Installation
UnitedStates/
Canada
Europe Japan/Taiwan
SEA/India /
Australia
China
1 LINE Black Brown Black Brown Brown
2 NEUTRAL White Blue White Blue Blue
3 Not Used Not Used Not Used Not Used Not Used Not Used
4 GROUND Green Green/Yellow Red Green/Yellow Green/Yellow
Pin Pin Name
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 mm
• Japan/Taiwan: 3 conductor, 1.25 mm
• SEA/India/Australia: 3 conductor, 1.5 mm
• China: 3 conductor, 1.5 mm
2
Agency Listed YZW cable with blue, brown, green/yellow insulation
2
Agency Listed H07RN-F cable with blue, brown, green/yellow insulation
2
Agency Listed 2 PNCT cable with black, white, red insulation
2
Agency Listed H07RN-F blue, brown, green/yellow insulation
Pin and Related Wire Color (F
IG. 3, page 11)
Color
10 332316C
(4)
(2)
(1)
1
2
3
4
Example Wiring Diagram
Connector on Housing
Connector on Cable
(4)
(1)
(3)
(2)
Installation
FIG. 3
332316C 11
Installation
United States /
Canada
Europe Japan / Taiwan
SEA / India /
Australia
China
1 -VDC Black Brown Black Brown Brown
2 +VDC White Blue White Blue Blue
3 Not Used Not Used Not Used Not Used Not Used Not Used
4 Not Used Green Green/Yellow Red Green/Yellow Green/Yellow
Pin Pin Name
Power DIN DC- 15 foot: Part No. 123358
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.
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 mm
• Japan/Taiwan: 3 conductor, 1/25 mm
• SEA/India/Australia: 3 conductor, 1.5 mm
2
• China: 3 conductor, 1.5 mm
Pin and Related Wire Color (F
Agency Listed YZW cable with blue, brown, green/yellow insulation
IG. 4, page 13)
2
Agency Listed H07RN-F cable with blue, brown, green/yellow insulation
2
Agency Listed 2 PNCT cable with black, white, red insulation
2
Agency Listed H07RN-F blue, brown, green/yellow insulation
Color
12 332316C
Installation
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)
FIG. 4
332316C 13
Installation
United States /
Canada
Europe Japan / Taiwan
SEA / India /
Australia
China
1 Not 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
4 Not Used Not Used Not Used Not Used Not Used Not Used
5 Not Used Not Used Not Used Not Used Not Used Not Used
6 Not Used Not Used Not Used Not Used Not Used Not Used
7 Not Used Green Green/Yellow Red Green/Yellow Green/Yellow
Pin Pin Name
Power CPC DC- 15 foot: Part No. 126217
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 F
• Secure socket connector to the cable per the desired strain relief configuration.
IG. 5 for proper location in the connector.
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 mm
• Japan/Taiwan: 3 conductor, 1/25 mm
• SEA/India/Australia: 3 conductor, 1.5 mm
• China: 3 conductor, 1.5 mm
2
Agency Listed YZW cable with blue, brown, green/yellow insulation
2
Agency Listed H07RN-F cable with blue, brown, green/yellow insulation
2
Agency Listed 2 PNCT cable with black, white, red insulation
2
Agency Listed H07RN-F blue, brown, green/yellow insulation
Pin and Related Wire Color (F
IG. 5, page 15)
Color
14 332316C
Installation
(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)
FIG. 5
332316C 15
Installation
Part No. 124333:
Cable Pin Out (M12) (FIG. 6)
Wire Colors
Item No. Color
1Brown
2White
3Blue
4Black
Part No. 124300:
Field Wireable Pin Out (M12) (FIG. 7)
Wire Colors
Item No. Color
1Brown
2White
3Blue
4Black
FIG. 7
FIG. 6
16 332316C
Installation
Part No. 124594:
4 Pin Eurofast Field Wireable Connector
(FIG. 8)
FIG. 8
Part No. 124595:
5 Pin Eurofast Field Wireable Connector
(FIG. 9)
FIG. 9
332316C 17
Setup
Setup
Pressure Relief
Follow the Pressure Relief Procedure whenever you see this symbol.
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.
Relieve pressure in system using two wrenches working 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 fitting.
Connecting to Auxiliary Fittings
NOTICE
Do not attach unsupported equipment to auxiliary fittings 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 element or auxiliary fittings. See F
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).
Pressure Relief Valves
IG. 10 for an exam-
NOTE: When loosening pump element fitting, do NOT
loosen pump element. Loosening pump element will
change the output volume.
FIG. 10
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.
18 332316C
Setup
37
max fill line
vent hole
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 (F
• Do not operate G1 without reservoir attached.
• 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.
Models without a follower plate:
1. Connect fill hose to inlet fitting *(37) (FIG. 11).
IG. 12).
NOTICE
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.
FIG. 12
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 controller specifications, to rotate stirring paddle during
fill to prevent air pockets from forming in grease.
FIG. 11
2. For higher viscosity fluids, start pump per your controller 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 (F
air is expelled from the reservoir.
FIG. 13
NOTE: Vent port, located in rear of reservoir, should not
be used as an overfill port/indicator.
4. Remove fill hose.
IG. 13) and the majority of
Changing Greases
When changing greases, always use compatible fluids
or greases.
332316C 19
Setup
a
b
Filling Oil Unit
• Only use oil 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 (F
• Do not operate G1 without reservoir attached.
• Only use oils with viscosity at least 40 cSt.
FIG. 14
1. Remove fill cap (a).
2. Pour oil into reservoir to fill line (b).
3. Replace fill cap. Hand tighten cap, securely.
IG. 14).
FIG. 15
2. Only run pump until air is no longer dispensed with
the lubricant coming out of element fitting (F
IG. 16).
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 (F
NOTE: When loosening pump element fitting, do NOT
loosen pump element. Loosening pump element will
change the output volume
20 332316C
IG. 15).
FIG. 16
3. Tighten pump element fitting using two wrenches
working in opposite directions (F
IG. 15).
No Controller Operation
200 ms
Open
Contact
Position
Closed
3 s
No Controller Operation
The G1 Pump can be controlled using an external, user
supplied, power source and controller.
Refer to the Typical Installation diagrams provided on
page 7 for correct location of the required pump ground
wire and fuses.
NOTE:
• When using an external power source and controller, Pump ON (Run) Time should be set for no longer than 30 minutes.
• In most cases, Pump OFF (Rest) Time should be
twice as long as Pump ON (Run) time. If alternative
ON / OFF times are required, contact Graco Customer Service for assistance.
Typical Low Level Output Response with Low Level Fluid in Grease Models
Low Level Output Option
Some G1 pumps without controllers include a Low Level
Output Option. The low level signal is monitored across
PINS 3 and 4. For PIN 3 and 4 locations and wiring
information the Low Level Outputs diagram.
NOTE: A low level warning is triggered when the controller detects PINS 3 and 4 have momentarily closed.
Grease Pumps
When the grease level has reached a low warning level,
PINS 3 and 4 momentarily close (1 time per paddle revolution) sending the signal that the fluid has reached a
low level to the controller.
To ensure that a low level condition has been met, 3 or
more low level triggers must be detected within 1 minute
or less.
See F
IG. 17 for an illustration of a typical Low Level Out-
put response to low grease level.
FIG. 17
332316C 21
No Controller Operation
Open
Closed
Oil Pumps
When the oil level has reached a low warning level,
PINS 3 and 4 close, sending the signal to the controller
that the fluid has reached a low level.
Typical Low Level Output Response with Low Level Fluid in Oil Models
To ensure that a low level condition has been met, the
low level trigger must be detected for 10 continuous seconds.
See F
IG. 18 for an illustration of a typical Low Level Out-
put response to low oil level.
Contact
Position
FIG. 18
22 332316C
Troubleshooting
Troubleshooting
Problem Cause Solution
Unit does not power on Incorrect/loose wiring Refer to Installation instructions, page 6.
Unit does not power on (DC models
only)
Tripped external fuse due to internal
component failure
Tripped external fuse due to pumping
non-cold weather lubricant in cold
weather -13°F (-25°C)
Contact Graco Customer Service.
Replace lubricant with pumpable lubricant, rated for environmental conditions
and application.
Replace fuse.
Unit does not power on (AC models
only)
Lubricant leaks past seal located on the
bottom of the reservoir
Follower plate is not going down
Pump takes several minutes before it
begins pumping
Tripped internal power supply fuse due
to power supply failure
Reservoir retaining tabs are cracked or
broken
Reservoir is being pressurized during
filling
Air is trapped in the reservoir between
the follower plate and lubricant
Pumping non-cold weather lubricant in
cold weather -13°F (-25°C)
Contact Graco Customer Service.
Replace reservoir.
Ensure vent hole is not plugged.
If problem persists, contact Graco Customer Service or your local Graco distributor for assistance.
Add grease following Loading Grease
instructions, page 19. Ensure air is
purged.
Increase pump on time.
Use grease suitable for temperature and
conditions.
332316C 23
Maintenance
Maintenance
Frequency Component Required Maintenance
Daily and at refill Zerk Fittings Keep all fittings clean using a clean
dry cloth. Dirt and/or debris can
damage pump and/or lubrication
system.
Daily G1 Pump Unit and Reservoir Keep pump unit and reservoir clean
using a clean dry cloth.
Monthly External Wiring Harness Verify external harnesses are
secure.
24 332316C
1
3
4
13
14
17
41
43
44
42
13
40b
40a
45
35
57
27
60
23
1615
37
67
66
Oil Reservoir
Follower Plate Models Only
Low Level Grease Models Only
Low Level Oil Models Only
Torque to 4 in. lbs (0.45 N.m)
1
Torque to 30 in. lbs (3.4 N.m)
2
Torque to 50 in. lbs (5.6 N.m)
3
3
2
1
3
33
Parts Drawing: 2 Liter Models
Parts Drawing: 2 Liter Models
332316C 25
Parts Drawing: 4 and 8 Liter Models
1
3
4
13
14
17
41
43
44
42
13
40b
40a
45
35
57
27
60
23
16
62
37
67
66
Oil Reservoir
Follower Plate Models Only
Low Level Grease Models Only
Low Level Oil Models Only
Torque to 4 in. lbs (0.45 N.m)
1
Torque to 30 in. lbs (3.4 N.m)
2
Torque to 50 in. lbs (5.6 N.m)
3
3
2
1
61
13
33
3
41
Parts Drawing: 4 and 8 Liter Models
26 332316C
Parts
Parts
FN Part No. Description Qty.
1 BASE, molded 1
3 278142 BOTTOM, cover 1
4 115477 SCREW, bottom cover 9
O-RING, 258 (green), included in Kit
124396
13
124510
14 PLATE, ricer 1
15 BEARING, ball 1
16
17 ELEMENT, pump 1
23‡ 278136 PADDLE, low level 1
27 123025 SCREW, M6 1
33 16A579 LABEL, safety 1
35
37 123741
40a
40b
40a
40b
571042, 571043, 571044, 571045,
571069, 571179
O-RING, included in Kit 571069,
571179, 571182, 571183
PADDLE, stirring, 2 liter models without follower plate, included in Kit
571044
PADDLE, stirring, 4 and 8 liter models without follower plate, included in
Kit 571046
PADDLE, stirring, 2 liter models with
follower plate, included in Kit 571045
PADDLE, stirring, 4 liter models with
follower plate, included in Kit 571047
WIPER, stirring, models without follower plate, included in Kit 571044,
571046
WIPER, stirring, models with follower
plate, included in Kit 571045, 571047
FITTING, zerk, grease models (not
included on oil models)
RESERVOIR, 2 liter, grease,
included in Kit 571042, 571069
RESERVOIR, 2 liter, oil, included in
Kit 571179
RESERVOIR, 4 liter, grease,
included in Kit 571183
RESERVOIR, 4 liter, oil, included in
Kit 571182
2
1
1
1
1
1
1
1
1
1
1
1
1
FN Part No. Description Qty.
278139 SEAL, follower plate, 2 liter models 1
41
16F472 SEAL, follower plate, 4 liter models 2
16V763 SEAL, follower plate, 8 liter models 2
42 PLATE, follower, grease models 1
43 ROD, follower plate, grease models 1
44
24D838 BAFFLE, low level, 2 liter models 1
45†
24E246 BAFFLE, low level, 4 liter models 1
24F836 BAFFLE, low level, 8 liter models 1
57 117156 BEARING, sleeve 1
58 196548 LABEL, shock warning 1
60 16D984 WASHER, low level models 2
61
62
66 126417 NUT 1
67 24N806 FLOAT, oil models 1
Replacement Danger and Warning labels, tags and cards
are available at no cost.
‡ Also order Ref 31 and Ref 34.
† Also order Ref. 57 when ordering this part.
SPRING, compression, grease models
RESERVOIR, mid-section, 8 liter
models
ADAPTER, reservoir 4 and 8 liter
models
1
1
1
40a RESERVOIR, 8 liter grease 1
40b
332316C 27
RESERVOIR, 8 liter, oil, included in
Kit 571182
1
Parts
a
ti15644
b
a = adjustment screw
b = locking nut
Pressure Relief Valves
Important Information regarding Pressure Relief
Valve 16C807.
Pressure Relief Valve 16C807 can only be used on
the G1 and G3 Pumps. It is not intended for use with
any other products.
The pressure relief valve uses a
pressure adjustment screw (a) to
set the pressure release point. It
is not intended as a way to
relieve pressure during normal
operation, but as a protective
measure in the event there is an
unintended pressure increase in
the system. Do not use this pressure relief valve a means of
relieving pressure in day-to-day,
normal cycle operation.
The pressure adjustment screw
will require periodic adjustments.
Whenever the valve is set/adjusted (after the set point is
found) it is important to ensure that the valve is not bottomed out and there is at least 1/2 turn of adjustment
remaining. This is determined by turning the screw (a)
1/2 turn and then back turning it out again.
NOTE: Turning adjustment screw (a) clockwise
increases pressure.
Part Description Qty
VALVE, pressure relief, 500-3500 psi (3.44
16C807◆
563156
563157
563158
563159
563160
563161
563190
MPa, 34.4 bar - 24.1 MPa, 241 bar), Set
pressure 3000 psi +
206.8 bar +
VALVE, pressure relief, 750 psi (5.17 MPa,
51.71 bar)
VALVE, pressure relief, 1000 psi (6.89
MPa, 68.95 bar)
VALVE, pressure relief, 1500 psi (10.34
MPa, 103.42 bar)
VALVE, pressure relief, 2000 psi (13.78
MPa, 137.89 bar)
VALVE, pressure relief, 2500 psi (17.23
MPa, 172.36 bar)
VALVE, pressure relief, 3000 psi (20.68
MPa, 206.84 bar)
VALVE, pressure relief, 5500 psi (37.92
MPa, 379.21 bar)
10%) Included in Kit 571028
10% (20.68 MPa,
1
1
1
1
1
1
1
1
Fuses
Part Description Qty
571039 FUSE, 12 volt DC
571040 FUSE, 24 volt DC
1
1
Installation and Repair Kits
Manual
Kit No. Description
571028
571071
571030 KIT, remote manual run, 12 volt DC
571031 KIT, remote manual run, 24 Volt DC
571036 KIT, cover with “G” label NA
571041
571042
571069
571044
571045
571046
571047
571058 KIT, output adapter, NPT
571070 KIT, output, adapter, BSPP
571060 KIT, fill, zerk, leakproof NA
571179
571183
KIT, return to reservoir NPT, includes
pressure relief valve 16C807
KIT, return to reservoir BSPP, includes
pressure relief valve 16C807
KIT, pump element, includes Ref 17,
18, 33
KIT, repair, 2 liter reservoir, includes
Ref 13, 36, 40
KIT, repair, 2 liter reservoir, for models
with follower plate, includes Ref 13, 36,
40
KIT, replacement, paddle, 2 liter, for
models without follower plate, includes
Ref 13, 16, 35, 57
KIT, replacement, paddle, 2 liter, for
models with follower plate, includes Ref
13, 16, 35,40a, 42, 57
KIT, replacement, paddle, 4-8 liter, for
models without follower plate, includes
Ref 13, 16, 35, 57
KIT, replacement, paddle, 4 liter, for
models with follower plate, includes Ref
13, 16, 35, 57
KIT, repair, reservoir oil, 2 liter models,
includes Ref 13, 36, 40b
KIT, repair, reservoir, oil 4 liter models,
includes Ref 13, 36, 40b
KIT, repair, reservoir, grease, 4 liter
models, includes Ref 13, 36, 40b
Number
3A0525
3A0528
3A0533
3A0534
3A0535
3A0522
3A0534571182
28 332316C
Technical Data
Technical Data
A
Maximum Working Pressure 5100 psi (35.1 MPa, 351.6 bar)
Power
100-240 VAC 88 - 264 VAC; 0.8 A current, 90 VA Power, 47/63 Hz,
Single phase, inrush/locked rotor, max 40A (1ms)
12 VDC 9 - 16 VDC; 5 A current, 60 W, inrush/locked rotor 12 A
24 VDC 18 - 32 VDC; 2.5 A current, 60 W, inrush/locked rotor 6 A
Fluid
Grease Models Grease NLGI 000 - #2
Oil Models At least 40 cSt oil.
Pumps 1
Pump Output
Pump Outlet 1/4-18 NPSF. Mates with 1/4-18 NPT male fittings
Reservoir Size 2 Liters, 4 Liters, 8 Liters
IP Rating IP69K
Ambient Temps -40°F - 158°F (-40°C to 70°C)
Weight (Dry)
Without follower plate 13.3 lbs (6.03 kg)
With follower plate 14.2 lbs (6.44 kg)
Wetted Parts nylon 6/6 (PA), trogamid T5004-060, zinc plated steel,
Sound Data <60 dB
3
0.25 in.
carbon steel, alloy steel, stainless steel, nitrile rubber (buna-N),
bronze, nickel plated alnico, chemically lubricated acetal, alumi-
num, PTFE, Grillamid
(4 cm3) / minute
Dimensions
Model
2L 13.25 33.65 8.00 20.32 9.00 22.86
4L 14.50 36.83 9.25 23.50 10.00 25.40
8L 18.50 47.00 9.25 23.50 10.00 25.40
Height Width Depth
Inches cm Inches cm Inches cm
332316C 29
Technical Data
0.367inch
9.3 mm
2x Ø 0.366 inch
9.3 mm
3.544 inch
90.0 mm
7.087 inch
180.0 mm
1.180 inch
30.0 mm
3.268 inch
83.0 mm
0.722 inch
18.3 mm
2x Ø 0.366 inch
9.3 mm
3.189 inch
81.0 mm
6.378 inch
162.0 mm
3.740 inch
95.0 mm
0.708 inch
18.0 mm
Option 1
Option 2
Mounting Pattern
For correct mounting configuration, choose either Option 1 or Option 2. See P/N 126916 template.
FIG. 19
30 332316C
Notes
Notes
332316C 31
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will
be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED
TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6928 or Toll Free: 1-800-533-9655, Fax: 612-378-3590
All written and visual data contained in this document reflects the latest product information available at the time of publication.
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2013, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Graco reserves the right to make changes at any time without notice.
For patent information, see www.graco.com/patents.
Original instructions. This manual contains English. MM 332316
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
www.graco.com
March 2013, revised June 2013
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