Instructions
™
G1 Plus
Lubrication Pump
332317C
EN
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
ANSI/UL 73
certified to
CAN/CSA
Std. 22.2 No 68-09
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Grease Models
Grease Models
Reservoir Size
Model
Voltage
Low
Level
CPC
DIN
Wiper Follower
100-240
VAC
2 Liter 4 Liter 8 Liter 12V DC 24V DC
94G000
94G001
94G002
94G003
94G004
94G005
94G012
94G013
94G014
94G015
94G016
94G017
94G024
94G025
94G026
94G027
94G028
94G029
94G048
94G049
94G050
94G051
94G052
94G053
94G054
94G055
94G056
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
332317C
3
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Oil Models
Oil Models
Reservoir Size
Voltage
Low
Level
CPC
DIN
Model
100-240
VAC
2 Liter 4 Liter 8 Liter 12V DC 24V DC
94G030
94G031
94G032
94G033
94G034
94G035
94G057
94G058
94G059
94G060
94G061
94G062
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
4
332317C
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Warnings
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.
332317C
5
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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.
6
332317C
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Installation
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
K
H
J
Oil Models
Grease Models
A
Grease Models with Follower
Plate
E
C
D
F
B
L
G
FIG. 1:
Key:
A
B
C
D
E
F
Reservoir
Pump Element
Pressure Relief Valve (Not included / required)
Zerk Inlet Fill Fitting (1 included / grease models only)
Power, DIN (if equipped)
H
Follower Plate (grease models only / not available on all
grease models)
Vent Hole
Fill cap (oil models only)
Control Panel
J
K
L
Power, CPC (if equipped)
G
Model Number/ Serial Number
332317C
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Installation
Typical Installation
B
C
D
A
A
B
Connected to fuse / power
Pressure relief valve (required, user supplied)
C
D
Series progressive divider valves
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 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.
•
•
Select a location that will adequately support the
weight of the G1 Pump and lubricant, as well as all
plumbing and electrical connections.
•
Use designated mounting holes and provided config-
urations only.
•
•
Always mount the G1 oil models upright.
Refer to the two mounting hole layouts provided in
the Mounting Pattern section of this manual, page 33.
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, oth-
erwise the G1 must be mounted upright.
NOTE: The two mounting hole layouts provided in the
Technical Data section show the only correct installa-
tion patterns to use for mounting the G1. No other
installation configurations should be used.
•
Use the three fasteners (included) to secure the G1
to the mounting surface.
8
332317C
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Installation
•
when repair or replacement of the power cord or
plug is required, do not connect the grounding wire
to either flat blade terminal.
System Configuration and
Wiring
Fuses
NOTICE
Fuses (user supplied) are required on all DC models.
To avoid equipment damage:
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.
•
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.
If the product is permanently connected:
•
it must be installed by a qualified electrician or ser-
viceman.
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.
•
it must be connected to a grounded, permanent wir-
ing system.
If an attachment plug is required in the end use
application:
Input Voltage
12 VDC
Fuse Value
Graco Kit No.
571039
7.5 A
•
•
•
it must be rated for the product electrical specifica-
tions.
24 VDC
4 A
571040
it must be an approved, 3-wire grounding type
attachment plug.
Recommendations for Using Pump in
Harsh Environments
it must be plugged into an outlet that is properly
installed and grounded in accordance with all local
codes and ordinances.
•
Use pump with CPC style power cable.
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
123358
DIN 15 ft.
Power DIN DC
Power CPC DC
126217
CPC 15 ft., 3-wire
123750
CPC 15 ft., 5-wire
126219
CPC 20 ft., 5-wire
16
16
Power CPC DC
126220
CPC 30 ft., 5-wire
332317C
9
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Installation
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
2
•
•
•
•
Europe: 3 Class-5 conductor, 1.5 mm Agency Listed H07RN-F cable with blue, brown, green/yellow insulation
2
Japan/Taiwan: 3 conductor, 1.25 mm Agency Listed 2 PNCT cable with black, white, red insulation
2
SEA/India/Australia: 3 conductor, 1.5 mm Agency Listed H07RN-F blue, brown, green/yellow insulation
2
China: 3 conductor, 1.5 mm Agency Listed YZW cable with blue, brown, green/yellow insulation
Color
Pin
Pin Name United States /
Canada
SEA / India /
Australia
Brown
Blue
Not Used
Europe
Japan / Taiwan
China
1
2
3
4
LINE
Black
White
Brown
Blue
Not Used
Green/Yellow
Black
White
Not Used
Red
Brown
Blue
Not Used
NEUTRAL
Not Used
GROUND
Not Used
Green
Green/Yellow Green/Yellow
10
332317C
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Installation
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
2
•
•
•
•
Europe: 3 Class-5 conductor, 1.5 mm Agency Listed H07RN-F cable with blue, brown, green/yellow insulation
2
Japan/Taiwan: 3 conductor, 1/25 mm Agency Listed 2 PNCT cable with black, white, red insulation
2
SEA/India/Australia: 3 conductor, 1.5 mm Agency Listed H07RN-F blue, brown, green/yellow insulation
2
China: 3 conductor, 1.5 mm Agency Listed YZW cable with blue, brown, green/yellow insulation
Color
Pin
Pin Name United States /
Canada
SEA / India /
Australia
Brown
Blue
Not Used
Europe
Japan / Taiwan
China
1
2
3
4
‐VDC
+VDC
Black
White
Brown
Blue
Not Used
Green/Yellow
Black
White
Not Used
Red
Brown
Blue
Not Used
Not Used
Not Used
Not Used
Green
Green/Yellow Green/Yellow
12
332317C
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Installation
Power CPC DC - 3-Wire, 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.
Secure socket connector to the cable per the desired strain relief configuration.
Cable Specifications
•
United States/Canada: 3 conductor 16 AWG UL62 and CSA 22.2 No. 49 listed SOOW cable with black, white,
green insulation
2
•
•
•
•
Europe: 3 Class-5 conductor, 1.5 mm Agency Listed H07RN-F cable with blue, brown, green/yellow insulation
2
Japan/Taiwan: 3 conductor, 1/25 mm Agency Listed 2 PNCT cable with black, white, red insulation
2
SEA/India/Australia: 3 conductor, 1.5 mm Agency Listed H07RN-F blue, brown, green/yellow insulation
2
China: 3 conductor, 1.5 mm Agency Listed YZW cable with blue, brown, green/yellow insulation
Color
Pin
Pin Name United States /
Canada
SEA / India /
Australia
Not Used
Brown
Europe
Japan / Taiwan
China
1
2
3
4
5
6
7
Not Used
‐VDC
Not Used
Black
Not Used
Brown
Not Used
Black
White
Not Used
Not Used
Not Used
Red
Not Used
Brown
+VDC
White
Blue
Blue
Blue
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Green
Not Used
Not Used
Not Used
Green/Yellow
Not Used
Not Used
Not Used
Not Used
Not Used
Not Used
Green/Yellow Green/Yellow
14
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Installation
Connector on Housing
Connector on Cable
(2)
(2)
(3)
(1)
(3)
(1)
(7)
(4)
(6)
(7)
(4)
(5)
(5)
(6)
Example Wiring Diagram
1
2
3
4
5
6
7
Ignition Switch
Fuse
12V-pump - 7.5A - Graco kit #571039
24V pump - 4A - Graco kit #571040
FIG. 4
332317C
15
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Installation
Power CPC DC - 5 wire
Part No.: 123750: 15 ft (4.5 m)
Part No.: 126219: 20 ft (6.1 m)
Part No.: 126220: 30 ft (9.1 m)
NOTE: An Illuminated Remote Run Button Kit: 571030, 571031 for starting a manual run cycle remotely if used in
conjunction with a 5-wire CPC cable, is available from Graco. Contact your local Graco distributor or Graco Customer
Service for additional information about these kits.
CPC Connector Specifications
•
•
•
One, 7-position, 1.5 mm socket connector AMP 967650-1
Five, 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.
Secure socket connector to the cable per the desired strain relief configuration.
Cable Specifications
•
•
•
United States/Canada: 5 conductor 16 AWG UL62 and CSA 22.2 No. 49 listed SOOW cable with black, white,
red, orange, green/yellow insulation
2
Europe: 5 Class-5 conductor, 1.5 mm Agency Listed H07RN-F cable with blue, brown, black, grey, green/yellow
insulation
2
Japan/Taiwan: 5 conductor, 1/25 mm Agency Listed 2 PNCT cable with black, white, red insulation, green,
black
2
•
•
SEA/India/Australia: 5 conductor, 1.5 mm Agency Listed H07RN-F black, white, red insulation, green, black
2
China:5 conductor, 1.5 mm Agency Listed YZW cable with black, white, red insulation, green, black
Color
Pin
Pin Name United States /
Canada
SEA / India /
Australia
Not Used
Brown
Blue
Black
Grey
Not Used
Europe
Japan / Taiwan
China
1
2
3
4
5
6
7
Not Used
‐VDC
Not Used
Black
Not Used
Brown
Blue
Black
Not Used
Black
White
Not Used
Brown
Blue
Black
Grey
+VDC
Red
LIGHT
White
Green
MANUAL
Not Used
Not Used
Orange
Not Used
Green
Grey
Not Used
Green/Yellow
Not Used
Not Used
Black
Not Used
Green/Yellow Green/Yellow
16
332317C
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Installation
Connector on Housing
Connector on Cable
(2)
(2)
(3)
(1)
(3)
(7)
(1)
(4)
(6)
(4)
(7)
(5)
(5)
(6)
Example Wiring Diagram
12V-pump - 7.5A - Graco kit #571039
24V pump - 4A - Graco kit #571040
Fuse
L
1
2
3
4
5
6
7
FIG. 5
332317C
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Setup
Connecting to Auxiliary Fittings
Setup
Pressure Relief
Follow the Pressure Relief Procedure when-
ever you see this symbol.
NOTICE
Do not attach unsupported equipment to auxiliary
fittings such as fill ports and pump element. Attach-
ing unsupported equipment to these fitting can
result in irreparable housing damage.
•
Always use two wrenches working in opposite
directions when connecting anything to pump
example.
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.
•
•
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).
Relieve pressure in system using two wrenches work-
ing in opposite directions on pump element and pump
element fitting to slowly loosen fitting only until fitting
is loose and no more lubricant or air is leaking from fit-
ting.
Pressure Relief Valves
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.
NOTE: When loosening pump element fitting, do NOT
loosen pump element. Loosening pump element will
change the output volume.
•
Only use a pressure relief valve that is rated for no
more than the working pressure of the G1 pump it
•
Install a pressure relief valve before any auxiliary
fitting.
FIG. 6
18
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Setup
3. Fill reservoir with NLGI grease to max fill line.
Loading Grease
NOTE: Vent port, located in rear of reservoir, should not
To ensure optimal performance from the G1:
be used as an overfill port/indicator.
•
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 operate G1 without reservoir attached.
NOTICE
max fill line
•
Always clean fitting (37) with a clean dry cloth
prior to filling reservoir. Dirt and/or debris can
damage pump and/or lubrication system.
FIG. 8
• Care must be used when filling the reservoir
using a pneumatic or electric transfer pump to
not pressurize and break the reservoir.
4. Remove fill hose.
Models with a follower plate:
Models without a follower plate:
2. For higher viscosity fluids, press the
manual run button to start the pump
during fill to rotate the stirring paddle
and prevent air pockets from forming in
grease.
3. Fill reservoir with grease until seal of follower plate
air is expelled from the reservoir.
37
FIG. 7
vent hole
2. For higher viscosity fluids, press the
manual run button to start the pump
during fill to rotate the stirring paddle
and prevent air pockets from forming in
grease.
FIG. 9
NOTE: Vent port, located in rear of reservoir, should not
be used as an overfill port/indicator.
4. Remove fill hose.
332317C
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Setup
Changing Greases
Priming
NOTE: It is not necessary to prime pump every time
When changing greases, always use compatible fluids
or greases.
pump is filled with lubricant.
Pump only requires priming the first time it is used or if it
is allowed to run dry.
Filling Oil Unit
•
Only use oil appropriate for your application, auto-
matic dispensing, and the equipment’s operating
temperature. Consult with machine and lube manu-
facturer for details.
NOTE: When loosening pump element fitting, do NOT
loosen pump element. Loosening pump element will
change the output volume
•
The reservoir can be filled using a hand operated
pump, pneumatic pump or electric transfer pump.
•
•
•
Do not operate G1 without reservoir attached.
Only use oils with viscosity at least 40 cSt.
a
b
FIG. 11
2. Only run pump until air is no longer dispensed with
FIG. 10
1. Remove fill cap (a).
2. Pour oil into reservoir to fill line (b).
3. Replace fill cap. Hand tighten cap, securely.
FIG. 12
3. Tighten pump element fitting using two wrenches
20
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Plus Model Control Setup
Plus Model Control Setup
OFF TIME
•
The blinking LED below OFF indicates the
OFF Time sequence is running.
Value is entered in HH.
ON TIME
•
•
•
•
•
The blinking LED below ON
indicates the ON Time
sequence is running.
Displays in HH.
Times pump rest between cycles.
Counts down from a set time to zero.
LOW LEVEL FAULT
•
Display shows time as MM
(minutes).
i.e., 02 is 2 minutes.
LED next to icon lights when
pump is out of lubricant. Pump
run cycle stops.
•
•
Times lubrication cycle.
Counts down from a set time to
zero.
ON
OFF
LOCK ICON
•
LED next to icon lights indi-
cating PIN is required to
enter setup.
MM
HH
•
In SETUP MODE LED
lights when setting up the
PIN.
Lubrication Pump
RIGHT DIRECTION ARROW /
MANUAL RUN / ENTER:
•
In SETUP MODE, saves
entry, moves cursor in display
one field to the right or to the
next setup step.
LEFT DIRECTION ARROW /
RESET
UP and DOWN ARROW
•
In SETUP MODE, moves cur-
sor in display one field to the
left.
•
•
Hold both the UP and DOWN ARROW but-
tons down together for 3 seconds to enter
SETUP MODE.
•
In RUN MODE starts a man-
ual run cycle.
•
In Low Level Fault Mode: press-
ing and holding for 3 seconds
clears fault and switches cycle
to OFF MODE.
In SETUP MODE, increases or decreases
number values shown in display.
FIG. 13
332317C
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Plus Model Control Setup
Entering a PIN Code to Access Setup Mode
Instructions
The G1 controller does not require a user to provide a
PIN code to access the programming features of the
unit. However, Graco understands that some users may
want to protect the program settings and therefore, an
option for adding PIN Code authorization is available.
The instructions for setting a PIN Code are provided in
the Advanced Programming section of this manual. See
Powering Units With Controllers
By default, units with controllers are set to
operate in a timed mode with 1 minute of
ON time and 8 hours of OFF time. The unit
should be powered up in OFF mode,
counting down from the 8 hours. If the unit powers up in
ON mode and has not been primed, hold the reset but-
ton located on the control panel (example shown on the
right) for 1 second to move to the OFF mode.
To enter the PIN Code:
1. Press both the UP and
DOWN ARROW buttons for 3
seconds.
The G1 Plus model uses a timer to regulate how long a
pump cycle runs and the length of time the pump rests
between cycles.
NOTE:
2. The LED next to the LOCK ICON on
the display lights and the 4 zeros
appear on the display indicating the
system requires a PIN Code entry to access the G1
in SETUP MODE.
•
A blinking number on the display indicates the G1 is
in SETUP MODE.
•
•
In RUN MODE numbers on the display do not blink.
After 60 seconds of no activity, the device returns to
RUN MODE in the OFF Time cycle and the OFF
Time restarts counting down the total programmed
amount of time. It does not resume the countdown
from the point where the cycle was interrupted when
you entered SETUP MODE.
3. The cursor is automatically
positioned to enter the first
character of the PIN Code.
Use the UP and DOWN
ARROW buttons to move up
and down through the numbers 0-9 until the first
number in the PIN code is displayed in the field.
Entering Setup Mode
4. Press the ENTER button to set the num-
ber. The cursor automatically moves to
the next number field.
Press both the UP and DOWN
ARROW buttons together for 3
seconds to enter the SETUP
MODE.
field.
NOTE: If the lock LED is lit after entering Setup Mode
and four 0000’s are displayed, the unit has a PIN Code
lock out enabled. See Entering a PIN Code to Access
Setup Mode for instructions on entering a value.
If the PIN Code you entered is correct, the first editable
character on the display will flash.
NOTE: A blinking field on the display indicates the G1 is
in SETUP MODE. In RUN MODE numbers on the dis-
play will not blink.
ON
OFF
MM
HH
22
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Plus Model Control Setup
ON Time
OFF Time
•
ON Time is set in Minutes (MM).
•
OFF Time is set in Hours (HH).
•
In SETUP MODE, the number dis-
played in the first field, on the left
side of display blinks, indicating the
device is ready to program the ON
Time minutes.
•
In SETUP MODE the number dis-
OFF
ON
played in the first field, on the left
side of display blinks, indicating the
device is ready to program the OFF
Time hours.
•
The total amount of ON Time can-
not exceed 30 minutes.
•
Total amount of OFF time cannot
exceed 24 hours.
HH
MM
Programming ON Time
Programming OFF Time
NOTE: When programming a time of less than 10 min-
utes you must program a leading zero in the first num-
ber field and press the ENTER button to save the zero
selection.
NOTE: When programming a time of less than 10
hours you must program a leading zero in the first num-
ber field and press the ENTER button to save the zero
selection.
1. To set the ON Time use the
UP or DOWN ARROW button
to scroll through numerals 0
to 3 until the desired number
appears in the first MM (min-
utes) field.
1. To set the OFF Time use the
UP or DOWN ARROW button
to scroll through numerals 0
to 9 until the desired number
appears in the first HH (hour)
field.
2. Press the ENTER button. The next MM
number field to the right flashes indicat-
ing it is ready for programming.
2. Press the ENTER button to lock in the
selection. The next HH number field to
the right flashes indicating it is ready for
programming.
3. Use the UP or DOWN
ARROW button to scroll
through numerals 0 to 9 until
the desired number appears
in the second MM number
field.
3. Use the UP or DOWN
ARROW button to scroll
through numerals 0 to 2 until
the desired number appears
in the second HH number
field.
4. After pressing the ENTER button to set
the last MM field, all the programmed
ON Time information is saved.
4. After pressing the ENTER button to set
the last HH field, the OFF Time infor-
mation is saved.
The G1 automatically switches to the OFF Time
SETUP MODE.
332317C
23
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Advanced Programming
Advanced Programming
Advanced
Option
Setting
Format/ Description
Why Use This?
Lockout
Code
(Optional)
Secures setup modes with
PIN
A1
Prevents unauthorized users to adjusting settings.
Entering a PIN Code for the First Time
Entering Advanced Setup
Press the UP ARROW button for 10 sec-
onds.
Setting Up PIN Code
A PIN Code can be programmed into the G1 to protect
the settings from inadvertently being changed by unau-
thorized users.
If the G1 was previously set up to require a
PIN Code, the LED next to the LOCK ICON
lights, indicating a PIN Code is required.
1. Press the UP ARROW button for 10
seconds.
1. The cursor is automatically
positioned to enter the first
character of the PIN Code.
Use the UP and DOWN
ARROW buttons to move up
and down through the numbers 0-9 until the first
number in the PIN code is displayed in the field.
The LED next to the LOCK ICON on the dis-
play lights, indicating you have entered the
PIN Mode.
2. The word OFF appears in the
display. Press the UP or
DOWN ARROW button to
change this to ON.
2. Press the ENTER button to set the num-
ber. The cursor automatically moves to
the next number field.
3. Press the ENTER button to enter the
PIN Code.
field.
If the PIN Code you entered is correct, the G1 will be in
the Advanced Setup option used to change the PIN
Code.
4. The cursor automatically is
positioned to entered the first
character of the PIN Code.
Use the UP and DOWN
A1 - Changing PIN Code .
ARROW buttons to move up
and down through the numbers 0-9 until the first
number in the PIN code is displayed in the field.
To change a PIN Code, follow instructions for Entering a
PIN Code for the first time.
5. Press the ENTER button to set the num-
ber. The cursor automatically moves to
the next number field.
field.
7. Press the ENTER button to save the
PIN Code and exit Advanced Setup.
24
332317C
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Run Mode
Low Level
Run Mode
Pumps equipped with low level detection will stop when
the fluid level is sufficiently low to trigger the low level
fault.
Time Control
After setup is complete, the G1 automatically begins to
run the OFF Time sequence.
•
The LED next to the LOW LEVEL
ICON on the display flashes.
•
The G1 runs the
programmed OFF
sequence.
Add lubricant to the pump. See Loading Grease
ON
OFF
•
After lubricant is added, press the
RESET button to clear the fault.
(Notice the dot
below OFF flashes
on the display
MM
HH
while the OFF
NOTE: For higher viscosity fluids it may be
necessary to clear the low level fault prior to
filling the pump. You can then press the
Manual Start button to start the pump during
the fill.
Time counts down.
This count down is in hours.)
•
When the OFF
Time count
ON
OFF
reaches zero, the
G1 Automatic
Manual Run Cycle
Lubrication Pump
turns the pump on
and it runs for the
programmed ON
Time cycle.
To run an extra (non-programmed) lubrica-
tion cycle, push the Manual Start button.
MM
HH
NOTE: An Illuminated Remote Run Button
Kit: 571030, 571031 for starting a manual run cycle
remotely if used in conjunction with a 5-wire CPC cable,
is available from Graco. Contact your local Graco distrib-
utor or Graco Customer Service for additional informa-
tion about these kits.
(Notice the dot below ON flashes on the display.)
•
•
When the ON Time count reaches zero, the pump
shuts off again and the system again runs OFF
Time cycle and the OFF Time LED flashes again.
This sequence repeats itself until the device is
reprogrammed or a Low Level Fault occurs.
If power to the pump is lost during a lubrication
cycle, when power is restored the pump will resume
the cycle with the same amount of time remaining in
the cycle as when the power was lost.
332317C
25
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Troubleshooting
Troubleshooting
Problem
Cause
Incorrect/loose wiring
Solution
Unit does not power on
Refer to Installation instructions, page 7.
Tripped external fuse due to internal
component failure
Contact Graco Customer Service.
Replace lubricant with pumpable lubri-
cant, rated for environmental conditions
and application.
Unit does not power on (DC models only)
Tripped external fuse due to pumping
non-cold weather lubricant in cold
weather -13°F (-25°C)
Replace fuse.
Tripped internal power supply fuse due to
power supply failure
Unit does not power on (AC models only)
Can’t set desired ON/OFF times
Contact Graco Customer Service.
Allowable ON time: 1-30 minutes
Allowable OFF time: 1-24 hours
(in full minute or hour increments)
Adhere to allowable duty cycle. Contact
Graco Customer Support if other duty
cycles are required for application.
Verify the unit was programmed as
intended, referencing programming
instructions.
Unit is not operating based on the time
that was programmed
Time entered was misinterpreted as MM
instead of HH (or visa versa)
Reservoir retaining tabs are cracked or
broken
Replace reservoir.
Ensure vent hole is not plugged.
Lubricant leaks past seal located on the
bottom of the reservoir
Reservoir is being pressurized during fill-
ing
If problem persists, contact Graco Cus-
tomer Service or your local Graco distrib-
utor for assistance.
Unit not pumping during ON cycle, but
controller lights and functions
Failed motor
Replace unit.
Add grease following Loading Grease
purged.
Air is trapped in the reservoir between
the follower plate and lubricant
Follower plate is not going down
Increase pump on time.
Pump takes several minutes before it
begins pumping
Pumping non-cold weather lubricant in
cold weather -13°F (-25°C)
Use grease suitable for temperature and
conditions.
Tripped internal, resettable fuse due to
Verify manual run inputs have not cre-
Dim display, unit is not operating
internal component failure or short circuit ated a short circuit condition. Cycle
condition
power.
Unit indicates a cycle or pressure alarm
before the lubrication cycle could com-
plete
Refer to programming ON Time, page
The ON Time was not entered correctly
26
332317C
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Maintenance
Maintenance
Frequency
Component
Zerk Fittings
Required Maintenance
Keep all fittings clean using a clean
dry cloth. Dirt and/or debris can dam-
age pump and/or lubrication system.
Daily and at refill
Keep pump unit and reservoir clean
using a clean dry cloth.
Daily
G1 Pump Unit and Reservoir
Display
Keep display clean using a clean dry
cloth.
Daily
Verify external harnesses are
secure.
Monthly
External Wiring Harness
332317C
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Parts: 2 Liter Models
Parts: 2 Liter Models
Oil Reservoir
43
40b
44
42
Low Level Grease Models Only
45
35
41
Follower Plate Models Only
23
27
1
57
40a
60
15
16
13
14
13
67
37
3
1
31
66
3
17
Low Level Oil Models Only
33
1
Torque to 4 in. lbs (0.45 N.m)
Torque to 30 in. lbs (3.4 N.m)
Torque to 50 in. lbs (5.6 N.m)
2
3
34
4
2
3
30
28
332317C
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Parts: 4 and 8 Liter Models
Parts: 4 and 8 Liter Models
Oil Reservoir
43
41
40b
44
Low Level Grease Models Only
45
41
42
Follower Plate Models Only
35
23
27
1
57
40a
60
61
16
13
62
67
13
14
13
66
3
37
1
31
Low Level Oil Models Only
17
3
33
1
Torque to 4 in. lbs (0.45 N.m)
Torque to 30 in. lbs (3.4 N.m)
Torque to 50 in. lbs (5.6 N.m)
2
3
34
4
3
30
2
332317C
29
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Parts
Parts
FN
Part No. Description
Qty.
FN
1
Part No. Description
Qty.
1
SEAL, follower plate, 2 liter grease
models
BASE, molded
278139
16F472
16V763
1
3
278142 BOTTOM, cover
115477 SCREW, bottom cover
1
SEAL, follower plate, 4 liter grease
models
4
9
41
2
O-RING, 258 (green), included in Kit
SEAL, follower plate, 8 liter grease
models
124396 571042, 571043, 571044, 571045,
571069, 571179
2
2
1
1
1
1
1
1
13
O-RING, included in Kit 571069,
124510
42
43
44
PLATE, follower, grease models
1
1
1
571179, 571182, 571183
ROD, follower plate, grease models
14
15
PLATE, ricer
SPRING, compression, grease mod-
els
BEARING, ball
PADDLE, stirring, 2 liter models with-
out follower plate, included in Kit
571044
24D838 BAFFLE, low level, 2 liter models
24E246 BAFFLE, low level, 4 liter models
24F836 BAFFLE, low level, 8 liter models
1
45†
PADDLE, stirring, 4 and 8 liter mod-
els without follower plate, included in
Kit 571046
1
1
16
PADDLE, stirring, 2 liter models with
follower plate, included in Kit 571045
57
117156 BEARING, sleeve
1
1
58
196548 LABEL, shock warning
PADDLE, stirring, 4 liter models with
follower plate, included in Kit 571047
ELEMENT, pump
1
1
60
61
16D984 WASHER, low level models
2
1
17
RESERVOIR, mid-section, 8 liter
models
23‡
278136 PADDLE, low level models
123025 SCREW, M6
1
1
1
2
1
1
ADAPTER, reservoir 4 and 8 liter
models
62
66
67
1
1
1
27
126417 NUT
30‡
31
262912 BOARD, circuit
24N806 FLOAT, oil models
119228 SCREW, machine, flat head
16A579 LABEL, safety
33
34
Replacement Danger and Warning labels, tags and cards
are available at no cost.
16T912 LABEL, overlay
‡ Also order Ref 31 and Ref 34.
WIPER, stirring, models without fol-
lower plate, included in Kit 571044,
571046
1
† Also order Ref. 57 when ordering this part.
35
WIPER, stirring, models with follower
plate, included in Kit 571045, 571047
1
1
1
1
1
1
1
1
FITTING, zerk, grease models (not
123741
37
included on oil models)
RESERVOIR, 2 liter, grease,
included in Kit 571042, 571069
40a
40b
40a
40b
40a
40b
RESERVOIR, 2 liter, oil, included in
Kit 571179
RESERVOIR, 4 liter, grease,
included in Kit 571183
RESERVOIR, 4 liter, oil, included in
Kit 571182
RESERVOIR, 8 liter grease
RESERVOIR, 8 liter, oil, included in
Kit 571182
30
332317C
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Parts
Pressure Relief Valves
Important Information regarding Pressure Relief
Valve 16C807.
Fuses
Part
Description
Qty
1
571039 FUSE, 12 volt DC
571040 FUSE, 24 volt DC
Pressure Relief Valve 16C807 can only be used on
the G1 and G3 Pumps. It is not intended for use with
any other products.
1
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 pres-
sure relief valve a means of
a
b
Installation and Repair Kits
Manual
Number
Kit No.
Description
KIT, return to reservoir NPT, includes
pressure relief valve 16C807
571028
3A0525
KIT, return to reservoir BSPP, includes
pressure relief valve 16C807
571071
571030 KIT, remote manual run, 12 volt DC
571031 KIT, remote manual run, 24 Volt DC
571036 KIT, cover with “G” label
3A0528
NA
ti15644
relieving pressure in day-to-day,
normal cycle operation.
a = adjustment screw
b = locking nut
KIT, pump element, includes Ref 17,
571041
18, 33
3A0533
The pressure adjustment screw
will require periodic adjustments.
KIT, repair, 2 liter reservoir, includes
Ref 13, 36, 40
571042
Whenever the valve is set/adjusted (after the set point is
found) it is important to ensure that the valve is not bot-
tomed 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.
3A0534
KIT, repair, 2 liter reservoir, for models
571069 with follower plate, includes Ref 13, 36,
40
KIT, replacement, paddle, 2 liter, for
571044 models without follower plate, includes
Ref 13, 16, 35, 57
NOTE: Turning adjustment screw (a) clockwise
increases pressure.
KIT, replacement, paddle, 2 liter, for
571045 models with follower plate, includes Ref
13, 16, 35,40a, 42, 57
3A0535
Part
Description
Qty
KIT, replacement, paddle, 4-8 liter, for
571046 models without follower plate, includes
Ref 13, 16, 35, 57
VALVE, pressure relief, 500-3500 psi (3.44
MPa, 34.4 bar - 24.1 MPa, 241 bar), Set
pressure 3000 psi + 10% (20.68 MPa,
206.8 bar + 10%) Included in Kit 571028
16C807
1
KIT, replacement, paddle, 4 liter, for
571047 models with follower plate, includes Ref
13, 16, 35, 57
VALVE, pressure relief, 750 psi (5.17 MPa,
51.71 bar)
563156
563157
563158
563159
563160
563161
563190
1
1
1
1
1
1
1
571058 KIT, output adapter, NPT
571070 KIT, output, adapter, BSPP
571060 KIT, fill, zerk, leakproof
3A0522
NA
VALVE, pressure relief, 1000 psi (6.89
MPa, 68.95 bar)
VALVE, pressure relief, 1500 psi (10.34
MPa, 103.42 bar)
KIT, repair, reservoir oil, 2 liter models,
571179
includes Ref 13, 36, 40b
VALVE, pressure relief, 2000 psi (13.78
MPa, 137.89 bar)
KIT, repair, reservoir, oil 4 liter models,
571182
3A0534
includes Ref 13, 36, 40b
VALVE, pressure relief, 2500 psi (17.23
MPa, 172.36 bar)
KIT, repair, reservoir, grease, 4 liter
571183
models, includes Ref 13, 36, 40b
VALVE, pressure relief, 3000 psi (20.68
MPa, 206.84 bar)
VALVE, pressure relief, 5500 psi (37.92
MPa, 379.21 bar)
332317C
31
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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)
9 - 16 VDC; 5 A current, 60 W, inrush/locked rotor 12 A
18 - 32 VDC; 2.5 A current, 60 W, inrush/locked rotor 6 A
12 VDC
24 VDC
Fluid
Grease Models
Oil Models
Pumps
Grease NLGI 000 - #2
At least 40 cSt oil.
1
3
3
Pump Output
0.25 in. (4 cm ) / minute
1/4-18 NPSF. Mates with 1/4-18 NPT male fittings
2 Liters, 4 Liters, 8 Liters
IP69K
Pump Outlet
Reservoir Size
IP Rating
Ambient Temps
Weight (Dry)
-40°F - 158°F (-40°C to 70°C)
Without follower plate
With follower plate
Wetted Parts
13.3 lbs (6.03 kg)
14.2 lbs (6.44 kg)
nylon 6/6 (PA), trogamid T5004-060, zinc plated steel,
carbon steel, alloy steel, stainless steel, nitrile rubber (buna-N),
bronze, nickel plated alnico, chemically lubricated acetal, alumi-
num, PTFE, Grillamid
Sound Data
<60 dB
Dimensions
Height
Width
Depth
Model
Inches
cm
Inches
cm
Inches
cm
2L
4L
8L
13.25
14.50
18.50
33.65
36.83
47.00
8.00
9.25
9.25
20.32
23.50
23.50
9.00
10.00
10.00
22.86
25.40
25.40
32
332317C
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Technical Data
Mounting Pattern
For correct mounting configuration, choose either Option 1 or Option 2. See P/N 126916 template.
Option 1
0.367inch
9.3 mm
7.087 inch
180.0 mm
2x Ø 0.366 inch
1.180 inch
30.0 mm
9.3 mm
3.268 inch
83.0 mm
3.544 inch
90.0 mm
Option 2
0.722 inch
18.3 mm
6.378 inch
162.0 mm
2x Ø 0.366 inch
9.3 mm
0.708 inch
18.0 mm
3.740 inch
95.0 mm
3.189 inch
81.0 mm
FIG. 14
332317C
33
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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
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 reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 332317
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
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.
March 2013, revised June 2013
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