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