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

Table of Contents

Table of Contents

Grease Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Oil Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Component Identification . . . . . . . . . . . . . . . 7

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 8

Choosing an Installation Location . . . . . . . . . . . . 8

System Configuration and Wiring . . . . . . . . . . . . 9

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . . . 18 Connecting to Auxiliary Fittings . . . . . . . . . . . . . 18 Loading Grease . . . . . . . . . . . . . . . . . . . . . . . . 19 Changing Greases . . . . . . . . . . . . . . . . . . . 20 Filling Oil Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Plus Model Control Setup . . . . . . . . . . . . . . . . . . . 21

Control Panel Overview (FIG. 13) . . . . . . . . . . . 21 Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Powering Units With Controllers . . . . . . . . . 22 Entering Setup Mode . . . . . . . . . . . . . . . . . 22 Entering a PIN Code to Access Setup Mode 22 ON Time . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 OFF Time . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Advanced Programming . . . . . . . . . . . . . . . . . . . . 24

Entering a PIN Code for the First Time . . . 24 Entering Advanced Setup . . . . . . . . . . . . . . 24

Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Low Level . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Manual Run Cycle . . . . . . . . . . . . . . . . . . . 25

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Parts: 2 Liter Models . . . . . . . . . . . . . . . . . . . . . . . 28

Parts: 4 and 8 Liter Models . . . . . . . . . . . . . . . . . . 29

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Pressure Relief Valves . . . . . . . . . . . . . . . . 31

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Installation and Repair Kits . . . . . . . . . . . . . 31

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Mounting Pattern . . . . . . . . . . . . . . . . . . . . . . . . 33

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 34

Oil Models

Oil Models

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.

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.

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

Oil Models

Grease Models

A

E

D

F

B

GL

FIG. 1:

H

J

Grease Models with Follower Plate

C

Key:

FPower, CPC (if equipped)

GModel Number/ Serial Number

Installation

Typical Installation

B

C

D

A

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.

???Refer to the two mounting hole layouts provided in the Mounting Pattern section of this manual, page 33.

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 designated mounting holes and provided config- urations 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, oth- erwise the G1 must be mounted upright.

???Use the three fasteners (included) to secure the G1 to the mounting surface.

System Configuration and

Wiring

.

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 ser- viceman.

???it must be connected to a grounded, permanent wir- ing system.

If an attachment plug is required in the end use application:

???it must be rated for the product electrical specifica- tions.

???it must be an approved, 3-wire grounding type attachment plug.

???it must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances.

Installation

???when repair or replacement of the power cord or plug is required, do not connect the grounding wire to either flat blade terminal.

Fuses

NOTICE

Fuses (user supplied) are required on all DC models. To avoid equipment damage:

???Never operate G1 Pump DC models without a fuse installed.

???A fuse of the correct voltage must be installed in line with the power entry to the system.

Fuse Kits are available from Graco. The following Table identifies the correct fuse to use for your input voltage and the corresponding Graco Kit number.

Recommendations for Using Pump in Harsh Environments

???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

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

???Europe: 3 Class-5 conductor, 1.5 mm2 Agency Listed H07RN-F cable with blue, brown, green/yellow insulation

???Japan/Taiwan: 3 conductor, 1.25 mm2 Agency Listed 2 PNCT cable with black, white, red insulation

???SEA/India/Australia: 3 conductor, 1.5 mm2 Agency Listed H07RN-F blue, brown, green/yellow insulation

???China: 3 conductor, 1.5 mm2 Agency Listed YZW cable with blue, brown, green/yellow insulation

Pin and Related Wire Color (FIG. 2, page 11)

Installation

Example Wiring Diagram

1

2

3

4

FIG. 2

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

???Europe: 3 Class-5 conductor, 1.5 mm2 Agency Listed H07RN-F cable with blue, brown, green/yellow insulation

???Japan/Taiwan: 3 conductor, 1/25 mm2 Agency Listed 2 PNCT cable with black, white, red insulation

???SEA/India/Australia: 3 conductor, 1.5 mm2 Agency Listed H07RN-F blue, brown, green/yellow insulation

???China: 3 conductor, 1.5 mm2 Agency Listed YZW cable with blue, brown, green/yellow insulation

Pin and Related Wire Color (FIG. 3, page 13)

Installation

Example Wiring Diagram

Ignition Switch

1

2

Fuse3

4

12V-pump - 7.5A - Graco kit #571039

24V pump - 4A - Graco kit #571040

FIG. 3

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.

???See Pin Layout shown in FIG. 4 for proper location in the connector.

???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

???Europe: 3 Class-5 conductor, 1.5 mm2 Agency Listed H07RN-F cable with blue, brown, green/yellow insulation

???Japan/Taiwan: 3 conductor, 1/25 mm2 Agency Listed 2 PNCT cable with black, white, red insulation

???SEA/India/Australia: 3 conductor, 1.5 mm2 Agency Listed H07RN-F blue, brown, green/yellow insulation

???China: 3 conductor, 1.5 mm2 Agency Listed YZW cable with blue, brown, green/yellow insulation

Pin and Related Wire Color (FIG. 4, page 15)

Installation

Example Wiring Diagram

FIG. 4

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.

???See Pin Layout shown in FIG. 5 for proper location in the connector.

???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

???Europe: 5 Class-5 conductor, 1.5 mm2 Agency Listed H07RN-F cable with blue, brown, black, grey, green/yellow insulation

???Japan/Taiwan: 5 conductor, 1/25 mm2 Agency Listed 2 PNCT cable with black, white, red insulation, green, black

???SEA/India/Australia: 5 conductor, 1.5 mm2 Agency Listed H07RN-F black, white, red insulation, green, black

???China:5 conductor, 1.5 mm2 Agency Listed YZW cable with black, white, red insulation, green, black

Pin and Related Wire Color (FIG. 5, page 17)

Installation

Connector on Cable

(2)

(7)

(3)

(1)

(4)

(6)(5)

Example Wiring Diagram

12V-pump - 7.5A - Graco kit #571039 Fuse 24V pump - 4A - Graco kit #571040

L

1

2

3

4

5

6

7

FIG. 5

Setup

Setup

Pressure Relief

Follow the Pressure Relief Procedure when- ever you see this symbol.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

Relieve pressure in system using two wrenches 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.

NOTE: When loosening pump element fitting, do NOT loosen pump element. Loosening pump element will change the output volume.

FIG. 6

Connecting to Auxiliary Fittings

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 element or auxiliary fittings. See FIG. 6 for an example.

???Torque pump element fittings to 50 in. lbs (5.6 N???m).

???When connecting pump element into housing torque to 50 in. lbs (5.6 N???m).

Pressure Relief Valves

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 26.

???Install a pressure relief valve before any auxiliary fitting.

Loading Grease

To ensure optimal performance from the G1:

???Only use NLGI #000 - #2 greases appropriate for your application, automatic dispensing, and the equipment???s operating temperature. Consult with machine and lube manufacturer for details.

???The reservoir can be filled using a hand operated pump, pneumatic pump or electric transfer pump.

???Do not overfill (FIG. 8).

???Do not operate G1 without reservoir attached.

NOTICE

???Always clean fitting (37) with a clean dry cloth prior to filling reservoir. Dirt and/or debris can damage pump and/or lubrication system.

???Care must be used when filling the reservoir using a pneumatic or electric transfer pump to not pressurize and break the reservoir.

Models without a follower plate:

1. Connect fill hose to inlet fitting (37) (FIG. 7).

37

FIG. 7

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.

Setup

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.

max fill line

FIG. 8

4. Remove fill hose.

Models with a follower plate:

1.Connect fill hose to inlet fitting (FIG. 7).

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 breaches the vent hole (FIG. 9) and the majority of air is expelled from the reservoir.

vent hole

FIG. 9

NOTE: Vent port, located in rear of reservoir, should not be used as an overfill port/indicator.

4. Remove fill hose.

Setup

Changing Greases

When changing greases, always use compatible fluids or greases.

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.

???The reservoir can be filled using a hand operated pump, pneumatic pump or electric transfer pump.

???Do not overfill (FIG. 10).

???Do not operate G1 without reservoir attached.

???Only use oils with viscosity at least 40 cSt.

a

b

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 (FIG. 11).

NOTE: When loosening pump element fitting, do NOT loosen pump element. Loosening pump element will change the output volume

FIG. 11

FIG. 10

1.Remove fill cap (a).

2.Pour oil into reservoir to fill line (b).

3.Replace fill cap. Hand tighten cap, securely.

2.Only run pump until air is no longer dispensed with the lubricant coming out of element fitting (FIG. 12).

FIG. 12

3.Tighten pump element fitting using two wrenches working in opposite directions (FIG. 11).

Plus Model Control Setup

Control Panel Overview (FIG. 13)

NOTE: Programming instructions begin on page 22.

OFF TIME

Plus Model Control Setup

ON TIME

???The blinking LED below ON indicates the ON Time sequence is running.

???Display shows time as MM (minutes).

i.e., 02 is 2 minutes.

??? Times lubrication cycle.

???Counts down from a set time to zero.

???The blinking LED below OFF indicates the OFF Time sequence is running.

???Value is entered in HH.

???Displays in HH.

???Times pump rest between cycles.

???Counts down from a set time to zero.

ON OFF

MM HH

Lubrication Pump

LOW LEVEL FAULT

LED next to icon lights when pump is out of lubricant. Pump run cycle stops.

LOCK ICON

???LED next to icon lights indi- cating PIN is required to enter setup.

???In SETUP MODE LED lights when setting up the PIN.

RIGHT DIRECTION ARROW /

MANUAL RUN / ENTER:

LEFT DIRECTION ARROW /

RESET

???In SETUP MODE, moves cur- sor in display one field to the left.

???In Low Level Fault Mode: press- ing and holding for 3 seconds clears fault and switches cycle to OFF MODE.

UP and DOWN ARROW

???Hold both the UP and DOWN ARROW but- tons down together for 3 seconds to enter

SETUP MODE.

???In SETUP MODE, increases or decreases number values shown in display.

???In SETUP MODE, saves entry, moves cursor in display one field to the right or to the next setup step.

???In RUN MODE starts a man- ual run cycle.

FIG. 13

Plus Model Control Setup

Instructions

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.

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:

???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.

Entering Setup Mode

Press both the UP and DOWN ARROW buttons together for 3 seconds to enter the SETUP MODE.

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.

ON OFF

MM HH

Entering a PIN Code to Access Setup Mode

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 page 24.

To enter the PIN Code:

1.Press both the UP and DOWN ARROW buttons for 3 seconds.

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.

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.

4.Press the ENTER button to set the num- ber. The cursor automatically moves to the next number field.

5.Repeat steps 3 and 4 for each PIN Code prompt field.

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 Time

???ON Time is set in Minutes (MM).

Programming ON 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.

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.

2.Press the ENTER button. The next MM number field to the right flashes indicat- ing 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.

4.After pressing the ENTER button to set the last MM field, all the programmed ON Time information is saved.

The G1 automatically switches to the OFF Time

SETUP MODE.

Plus Model Control Setup

OFF Time

???OFF Time is set in Hours (HH).

Programming OFF Time

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 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 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 2 until the desired number appears in the second HH number field.

4.After pressing the ENTER button to set the last HH field, the OFF Time infor- mation is saved.

Advanced Programming

Advanced Programming

Entering a PIN Code for the First Time

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.

1.Press the UP ARROW button for 10 seconds.

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.

3.Press the ENTER button to enter the PIN Code.

4.The cursor automatically is positioned to entered 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.

5.Press the ENTER button to set the num- ber. The cursor automatically moves to the next number field.

6.Repeat steps 4 and 5 for each PIN Code prompt field.

7.Press the ENTER button to save the PIN Code and exit Advanced Setup.

Entering Advanced Setup

Press the UP ARROW button for 10 sec- onds.

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.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.

2.Press the ENTER button to set the num- ber. The cursor automatically moves to the next number field.

3.Repeat steps 1 and 2 for each PIN Code prompt field.

If the PIN Code you entered is correct, the G1 will be in the Advanced Setup option used to change the PIN Code.

A1 - Changing PIN Code .

To change a PIN Code, follow instructions for Entering a PIN Code for the first time.

Run Mode

Time Control

After setup is complete, the G1 automatically begins to run the OFF Time sequence.

This count down is in hours.)

???When the OFF

(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.

Run Mode

Low Level

Pumps equipped with low level detection will stop when the fluid level is sufficiently low to trigger the low level fault.

???The LED next to the LOW LEVEL

ICON on the display flashes.

Add lubricant to the pump. See Loading Grease instructions, page 19 or Filling Oil Unit, page 20.

???After lubricant is added, press the RESET button to clear the fault.

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.

Manual Run Cycle

To run an extra (non-programmed) lubrica- tion cycle, push the Manual Start button.

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.

Troubleshooting

Troubleshooting

Parts: 2 Liter Models

Parts: 2 Liter Models

Oil Reservoir

43

40b

Low Level Grease Models Only

45

41

Follower Plate Models Only

40a

15

67

3 37

31

66

Low Level Oil Models Only

30

35

57 271

60

16

13

14

13

1

17 3

33

23

Parts: 4 and 8 Liter Models

Parts: 4 and 8 Liter Models

Oil Reservoir

43

41

40b

44

Low Level Grease Models Only

41

45

Parts

Parts

???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.

a = adjustment screw
b = locking nut
The pressure adjustment screw will require periodic adjustments.
Whenever the valve is set/adjusted (after the set point is found) it is important to ensure that the valve is not 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.
NOTE: Turning adjustment screw (a) clockwise increases pressure.

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.

Parts

Fuses

Installation and Repair Kits

Technical Data

Technical Data

Dimensions

Technical Data

Mounting Pattern

For correct mounting configuration, choose either Option 1 or Option 2. See P/N 126916 template.

Option 1

2x ?? 0.366 inch

9.3 mm1.180 inch

30.0 mm

3.268 inch

83.0 mm

3.544 inch

90.0 mm

Option 2

2x ?? 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

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 r??daction du pr??sente document sera en Anglais, ainsi que tous documents, avis et proc??dures judiciaires ex??cut??s, donn??s ou intent??s, ?? la suite de ou en rapport, directement ou indirectement, avec les proc??dures concern??es.

Graco Information

For the latest information about Graco products, visit www.graco.com.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 612-623-6928 or Toll Free: 1-800-533-9655, Fax: 612-378-3590

All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco 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 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.

www.graco.com

March 2013, revised June 2013