Graco G1 Instructions Manual

Instructions

3132066
conforms to AN­SI/UL 73
certified to
CAN/CSA
Std. 22.2 No 68-09

™

G1

Standard

332316E

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 Wor king 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 332316E

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

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

332316E 3

2 Liter 4 Lit er 8 Liter 12V DC 24V DC 100-240

VAC

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, ref er bac k to these W arnings. Prod uct-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 Tec h nical 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 en vironment 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 332316E

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 , glo ve, 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.

332316E 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 escap e 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 incl uded / 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 Follow er Pl at e (grease models only / not available on all

grease models)
K Vent Hole
L Fill cap (oil models only)

6 332316E

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 injectio n an d am p ut at ion .
This device has an automatic timer that activates the pump lubrication system when powe r is connected or when e xit-

ing the programming function. Before you install or remo ve 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 mou nting hole la y outs pro vided
in the Mounting Pattern section of this manual,
page 30.

NOTE: T he 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 provid ed
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 (include d) to secure the
G1 to the mounting surface.

332316E 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 tha t 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 m ust 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 voltag e
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 prev entat iv e electrical grease on all
contacts.

8 332316E

Installation

Wiring and Installation Diagrams

NOTE: Graco doe s not pro vide a po wer cab le with th e G1. Power cables are av ailab le f or purcha se from Gr aco or the

user may prov ide their o wn. See Table 1 f or ref er ence pages cont aining additi onal inf ormation related to G raco po wer
cables.

Table 1: Graco Power Cables

Cable Part No. Diagram Symbol Page #

Power DIN AC 10

123358

DIN 15 ft.

Power DIN DC 12

127783

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

332316E 9

Installation

Uni tedStates/

Canada

Europe Japan/Taiwan

SEA/India/

Australia

China

1 LINE Black Brown Black Brown Brown
2 NEUTRAL White Blue White Blue Blue
3NotUse d NotUsed NotUse d NotUsed NotUse d NotUse d
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 cabl e 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 332316E

(4)

(2)

(1)

1

2

3

4

Example Wiring Diagram

Connector on Housing

Connector on Cable

(4)

(1)

(3)

(2)

Installation

FIG. 3

332316E 11

Installation

Uni tedStates/

Canada

Europe Japan/Taiwan

SEA/India/

Australia

China

1 ‐VDC Black Brown Black Brown Brown
2 +VDC White Blue White Blue Blue
3NotUse d NotUsed NotUse d NotUsed NotUsed NotUse d
4Not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

• China: 3 conductor, 1.5 mm

Pin and Related Wire Color (F

2

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 332316E

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

332316E 13

Installation

Uni tedStates/

Canada

Europe Japan/Taiwan

SEA/India/

Australia

China

1NotUse d NotUsed NotUse d NotUsed NotUsed NotUsed
2 ‐VDC Black Brown Black Brown Brown
3 +VDC White Blue White Blue Blue
4NotUse d NotUsed NotUse d NotUsed NotUsed NotUsed
5NotUse d NotUsed NotUse d NotUsed NotUsed NotUsed
6NotUse d NotUsed NotUse d NotUsed NotUsed NotUsed
7NotUsed Green Green/Yellow Red Green/Yellow Green/Yellow

Pin PinName

Power CPC DC- 15 foot: Part No. 127783

CPC Connector Specifications

• One, 7-position, 1.5 mm soc ket connector AMP 967650-1

• Three, 16 - 14 gauge female pins AMP 962999-1

• One, 180-degree str ain relief or one, 90-degree str ain 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 332316E

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

332316E 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 332316E

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

332316E 17

Setup

Setup

Pressure Relief

Follow the Pressure Relief Procedure when­ever you see this symbol.

This equipment stays pressurized un til pressure is
manually relieved. T o help prevent serious injury
from pressurized fluid, such as skin injection,
splashing fluid and moving par ts, 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 w orking in opposite
directions when connecting anything to pump ele­ment or auxiliary fittings. See F
ple.

• Torque pump element fitt ing s 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 elem ent 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 332316E

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 t he
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 att ached.

• A lways 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 pu mp 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.

332316E 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 att ached.

• 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 elem ent fitting, do NOT

loosen pump element. Loosening pump element will
change the output volume

20 332316E

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 e xternal, 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 assistan ce.

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 w arning 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.

IG. 17 for an illustration of a typical Low Level Out-

See F
put response to low grease level.

FIG. 17

332316E 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 lev el t rigger m ust be de tect ed for 10 continuous sec­onds.

IG. 18 for an illustration of a typical Low Level Out-

See F
put response to low oil leve l.

Contact
Position

FIG. 18

22 332316E

Troubleshooting

Troubl eshooting

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 Se rvice.

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 Se rvice.

Replace reservoir.

Ensure vent hole is not plugged.
If problem persists, contact Graco Cus-

tomer 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.

332316E 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 lubricat ion
system.

Daily G1 Pump Unit and Reservoir Keep pump unit and rese rvoir clea n

using a clean dry cloth.

Monthly External Wiring Harness Ver ify external har nesses are

secure.

24 332316E

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

332316E 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 332316E

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

332316E 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 t he va lv e is set/adjusted ( after the set poin t 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

V ALVE, 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 +
V ALVE, pressure relief, 750 psi (5.17 MPa,

51.71 bar)
V ALVE, 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 mo dels
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 332316E

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), amorphous polyamide, 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, PT FE

(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

332316E 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 Part Number 126916 template.

FIG. 19

30 332316E

Notes

Notes

332316E 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 WA RRANTY 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 manufacture r. 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 ex écutés, 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: [phone] or Toll Free: 1-800-533-9655, Fax: [phone]

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

International Offices: Belgium, China, Japan, Korea

Graco Headquarters: Minneapolis

www.graco.com

March 2013, revised October 2015