Graco G3 Series User manual

Conforms to ANSI/UL 73

Certified to CAN/CSA

Std. 22.2 No 68-09

3132066

24V and 110-240VAC Pumps ONLY

332291P

Instructions

G3 Standard Automatic

Lubrication Pump

For dispensing of NLGI Grades #000 to #2 greases and oils with at least 40cSt. For

professional use only.

Not approved for use in explosive atmospheres or hazardous (classified) locations.

Part Nos., page 3

5100 psi (35.1 MPa, 351.6 bar) Pump Output Pressure

5000 psi (34.3 MPa, 344.8 bar) Fill Inlet Pressure

Important Safety Instructions

Read all warnings and instructions in this

manual before using the equipment.

Save these instructions.

2 332291P

Contents

Part / Model Numbers . . . . . . . . . . . . . . . . . . . . . . . 3

2 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

8 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

12 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 4

16 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Understanding the Model Number . . . . . . . . . . . 5

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 10

Typical Installation - With Remote

Fill Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 11

Optional Installation - Without Remote

Fill Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 12

Choose an Installation Location . . . . . . . . . . . . 13

System Configuration and Wiring . . . . . . . . . . . 13

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Pressure Relief Procedure . . . . . . . . . . . . . . . . . 19

Connect to Auxiliary Fightings . . . . . . . . . . . . . . 19

Set Pump Outlet Volume . . . . . . . . . . . . . . . . . . 20

Load Pump with Grease . . . . . . . . . . . . . . . . . . 20

Auto-Fill Shut Off . . . . . . . . . . . . . . . . . . . . . . . . 23

Fill the Oil Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Prime the Pump . . . . . . . . . . . . . . . . . . . . . . . . . 26

Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Recycling and Disposal . . . . . . . . . . . . . . . . . . . . . 29

End of Product Life . . . . . . . . . . . . . . . . . . . . . . 29

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Parts - 2 Liter Models. . . . . . . . . . . . . . . . . . . . . . . 32

Parts - 4 Liter and Larger Models . . . . . . . . . . . . . 33

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Mounting Pattern . . . . . . . . . . . . . . . . . . . . . . . . 38

Technical Specifications . . . . . . . . . . . . . . . . . . . . 40

California Proposition 65 . . . . . . . . . . . . . . . . . . 41

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 42

332291P 3

Part / Model Numbers

The Part Number is a six-digit unique number that is only used to order the G3 Pump. Directly related to this six digit Part Num-

ber is the configured Graco Model Number. This configured number identifies the distinct features of a specific G3 Pump. To

help you understand each component that makes up the Model Number see Understanding the Model Number, page 5. The

tables below shows the relationship between each Part Number and its related Model Number.

2 Liter Models 4 Liter Models

Part

Numbers Model Number

96G000 G3-G-12NC-2L0000-00C00000

96G001 G3-G-24NC-2L0000-00C00000 X

96G002 G3-G-ACNC-2L0000-0D000000 X

96G003 G3-G-12NC-2L0A00-L0C00000

96G005 G3-G-24NC-2L0A00-L0C00000 X

96G006 G3-G-24NC-2LFA00-L0C00000 X

96G007 G3-G-ACNC-2L0A00-LD000000 X

96G008 G3-G-ACNC-2LFA00-LD00000 X

96G050 G3-A-24NC-2L0A00-L0C00000 X

96G059 G3-A-ACNC-2L0A00-LD000000 X

96G182 G3-G-24NC-2L0A00-0D00L000 X

96G239 G3-G-24NC-2L0A06-00C00000 X

96G243 G3-G-24NC-2L0A00-0D00L000 X

96G261 G3-G-24NC-2L0A07-L0C00000 X

Part

Numbers Model Number

96G038 G3-G-12NC-4L0L00-00C00000

96G040 G3-G-24NC-4L0000-00C00000 X

96G042 G3-G-ACNC-4L0000-0D000000 X

96G044 G3-G-12NC-4L0A00-L0C00000

96G048 G3-G-24NC-4L0A00-L0C00000 X

96G051 G3-A-24NC-4L0A00-L0C00000 X

96G053 G3-G-24NC-4LFA00-L0C00000 X

96G055 G3-G-ACNC-4L0A00-LD000000 X

96G060 G3-A-ACNC-4L0A00-LD000000 X

96G062 G3-G-ACNC-4LFA00-LD000000 X

96G173 G3-G-ACNC-4LFA00-0D00L000 X

96G179 G3-G-ACNC-4LFA00-0D00L000 X

96G184 G3-G-24NC-4L0A00-0D00L000 X

96G210 G3-G-24NC-4LAA00-0D00L000 X

96G180 G3-G-24NC-4L0A02-L0C00000 X

96G202 G3-G-ACNC-4L0A00-0D00L000 X

96G204 G3-G-24NC-4LFA00-0D00L000 X

96G238 G3-G-24NC-4L0A06-00C00000 X

96G248 G3-G-24NC-4L0A02-L0C00000 X

96G250 G3-G-24NC-4LFA07-0D00L000 X

96G273 G3-G-12NC-4L0A10-00C00000

96G276 G3-G-24NC-4L0A07-0D00L000 X

96G277 G3-G-24NC-4LLA06-00C00000

96G278 G3-G-24NC-4LHA06-00C00000

96G280 G3-G-24NC-4LHA00-0D00L000

96G287 G3-G-24NC-4L0A10-00C00000

4 332291P

8 Liter Models 12 Liter Models

16 Liter Models

Part

Numbers Model Number

96G039 G3-G-12NC-8L0000-00C00000

96G041 G3-G-24NC-8L0000-00C00000 X

96G043 G3-G-ACNC-8L0000-0D000000 X

96G045 G3-G-12NC-8L0A00-L0C00000

96G049 G3-G-24NC-8L0A00-L0C00000 X

96G052 G3-A-24NC-8L0A00-L0C00000 X

96G056 G3-G-ACNC-8L0A00-LD000000 X

96G061 G3-A-ACNC-8L0A00-LD000000 X

96G187 G3-G-ACNC-8LFA00-0D00L000 X

96G189 G3-G-24NC-8L0A00-0D00L000 X

96G192 G3-G-24NC-8LFA00-L0C00000 X

96G198 G3-G-24NC-8L0A06-0C000000 X

96G207 G3-G-ACNC-8LAA00-LD000000 X

96G213 G3-G-24NC-8LAA00-0D00L000 X

96G217 G3-G-24NC-8LAA06-00C00000 X

96G205 G3-G-24NC-8LFA00-0D00L000 X

96G233 G3-G-12NC-8L0A00-0D00L000

96G262 G3-G-24NC-8LLA06-00C00000

96G249 G3-G-24NC-8L0A07-0D00L000 X

96G251 G3-G-24NC-8LFA07-0D00L000 X

96G271 G3-G-24NC-8LFA07-00C00000 X

96G272 G3-G-24NC-8LFA10-00C00000

96G279 G3-G-24NC-8LHA06-00C00000

96G281 G3-G-24NC-8LHA00-0D00L000

96G290 G3-G-24NC-8LAA10-00C00000

Part

Numbers Model Number

96G057 G3-G-ACNC-120A00-LD000000 X

96G171 G3-G-24NC-120000-00C00000 X

96G199 G3-G-24NC-120A00-L0C00000 X

96G240 G3-G-24NC-120A00-0D00L000 X

Part

Numbers Model Number

96G058 G3-G-ACNC-160A00-LD000000 X

96G172 G3-G-24NC-160000-00C00000 X

96G220 G3-G-24NC-160A00-L0C00000 X

96G230 G3-G-12NC-160A00-0D00000

96G237 G3-G-ACNC-16AA00-LD000000 X

96G241 G3-G-24NC-160A00-0D00L000 X

96G258 G3-A-24NC-160A00-L0C00000 X

332291P 5

Understanding the Model Number

Use the Code Sample provided below to identify each component’s location in the Model Number. The options for

each component that make up the code are provided on the lists below.

NOTE: Other pump configurations are available that are not documented in this manual. Contact Graco Customer

Service or your local Graco distributor for assistance.

Code a: Pump Fluid Type

• G = Grease

• A = Oil

Code bb: Power Source

• 12 = 12 Volts DC

• 24 = 24 Volts DC

• AC = 100 - 240 Volts AC

Code cc: Operation Control

• NC = No Controller

Code dd: Reservoir Capacity (Liters)

• 2L = 2 Liters

• 4L = 4 Liters

• 8L = 8 Liters

• 12 = 12 Liters

• 16 = 16 Liters

Code e: Reservoir Feature

• F = Follower Plate Installed

• 0 = No Follower Plate

• A = Auto-Fill Shut Off

• L = Top Fill

• H = Hammer Pump

Code f: Low Level Option

• A = External Low Level

• 0 = No Low Level monitoring

Code gg: Options

• 00 = No Options

• 06 = Low Level in CPC

Code h, i, j, k, m, n, p, q

NOTE: Codes h - q relate to a specific location on the

G3 pump. See FIG. 1 for these locations.

• C = CPC

• D = DIN

• L = Low Level

• 0 = Not populated

G 3 - - N C 0 0 0 0 0 0

Code Sample: a b b c c - d d e f g g - h i j k m n p q

FIG. 1

Warnings

6 332291P

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The

exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks.

When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings.

Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this

manual where applicable.

WARNING

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause

electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing

or installing equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and

regulations.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system

component. See Technical Specifications in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical

Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For

complete information about your material, request Safety Data Sheets (SDSs) from distributor or

retailer.

• 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

332291P 7

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 the Pressure Relief Procedure in this manual before servicing.

PLASTIC PARTS CLEANING SOLVENT HAZARD

Many cleaning solvents can degrade plastic parts and cause them to fail, which could cause serious

injury or property damage.

• Use only compatible solvents to clean plastic structural or pressure-containing parts.

• See Technical Specifications in all equipment manuals for materials of construction. Consult the

solvent manufacturer for information and recommendations about compatibility.

WARNING

Warnings

8 332291P

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the

Pressure Relief Procedure and disconnect all power sources.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including

eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective 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.

WARNING

Installation

332291P 9

Installation

Component Identification

Key:

A Reservoir

B Adjustable Pump Element (1 included. Can

accommodate 3 total)

C Pressure Relief Valve (Not included (not shown) / required

for each outlet - Available from Graco. See Parts, page

35.)

D Zerk Inlet Fill Fitting (1 included / grease models only)

E Pump Outlet Plug (2 included)

F Volume Control Spacers (2 included. More spacers = less

output volume per stroke) (also see FIG. 18, page 20)

G Fuse (DC models only - Not included, not shown.

Available from Graco. See Parts, page 34.)

H Power / Sensor Panel (both sides; only one side shown)

I Part Number / Model Number example only shown, (see

page 5, Understanding the Model Number, for details)

J Power Cord (Not shown)

K Follower Plate (grease models only / not available on all

grease models)

L Vent Hole for Follower Plate (grease models only / not

available on all grease models)

M Fill cap (oil models only)

N Auto-Fill Shut Off

P Top Fill Lid

FIG. 2

G3-G-24NC-2L0A00-L0C00000

96GXXX

Grease Models

Auto-Fill Shut Off Models

Grease Models with

Follower Plate

Oil Models Top Fill Models

Installation

10 332291P

Typical Installation

Series Progressive Divider Valve

Injector Installations

Key

A Connected to fused power source

B Pressure relief valve (Not included/ required for each out-

let - user supplied. See Parts, page 35)

C Supply Hose (user supplied)

D Series progressive divider valves (Divider Installations)

- Injectors (Injector Installations)

E To lube points

F - Proximity Switch (Divider Installations)

- Pressure switch (Injector Installations)

G Vent valve (Not included / available from Graco. See

Parts, page 36.)

H Return to reservoir

FIG. 3

FIG. 4

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