Graco 332291B User Manual

Instructions

TI14705

Conforms to ANSI/UL 73 Certified to CAN/CSA Std. 22.2 No 68-09

3132066

G3 Standard Automatic

332291B

Lubrication Pump

For dispensing of NLGI Grades #000 to #2 greases and oil with at least 40cSt. For Professional Use Only.

Not approved for use in explosive atmospheres or hazardous locations.

Part Nos., page 3

5100 psi (35.1 MPa, 351.6 bar) Maximum Working Pressure

Important Safety Instructions Read all warnings and instructions in this

manual. Save these instructions.

Contents

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

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

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

8 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

12 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 3

16 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Understanding the Model Number . . . . . . . . . . . 4

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

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

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

Choosing an Installation Location . . . . . . . . . . . . 9

System Configuration and Wiring . . . . . . . . . . . 10

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

Connecting to Auxiliary Fittings . . . . . . . . . . . . . 18

Setting Pump Outlet Volume . . . . . . . . . . . . . . . 19

Loading Grease . . . . . . . . . . . . . . . . . . . . . . . . 19

Filling Oil Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

No Controller Operation . . . . . . . . . . . . . . . . . . . . 22

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Parts - 2 Liter Models . . . . . . . . . . . . . . . . . . . . . . 26

Parts - 4 Liter and Larger Models . . . . . . . . . . . . . 27

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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

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

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

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

Graco Information . . . . . . . . . . . . . . . . . . . . . . . 34

2 332291B

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 Number 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 Your Model Number, page 4. The tables below shows the relationship between each Part Number and its related Model Number.

2 Liter Models

Part

Numbers

96G000 G3-G-12NC-2L0000-00C00000 96G001 G3-G-24NC-2L0000-00C00000 96G002 G3-G-ACNC-2L0000-0D000000 96G003 G3-G-12NC-2L0A00-L0C00000 96G005 G3-G-24NC-2L0A00-L0C00000 96G006 G3-G-24NC-2FA00-L0C00000 96G007 G3-G-ACNC-2L0A00-LD000000 96G008 G3-G-ACNC-2LFA00-LD00000 96G050 G3-A-24NC-2L0A00-L0C00000 96G059 G3-A-ACNC-2L0A00-LD000000 96G182 G3-G-24NC-2L0A00-0D00L000

Model Number

4 Liter Models

Part

Numbers

96G038 G3-G-12NC-4L0L00-00C00000 96G040 G3-G-24NC-4L0000-00C00000 96G042 G3-G-ACNC-4L0000-0D000000 96G044 G3-G-12NC-4L0A00-L0C00000 96G048 G3-G-24NC-4L0A00-L0C00000 96G051 G3-A-24NC-4L0A00-L0C00000 96G053 G3-G-24NC-4LFA00-L0C00000 96G055 G3-G-ACNC-4L0A00-LD000000 96G060 G3-A-ACNC-4L0A00-LD000000 96G062 G3-G-ACNC-4LFA00-LD000000 96G179 G3-G-ACNC-4LFA00-0D00L000 96G184 G3-G-24NC-4L0A00-0D00L000

Model Number

8 Liter Models

Part

Numbers

96G039 G3-G-12NC-8L0000-00C00000 96G041 G3-G-24NC-8L0000-00C00000

96G043 96G045 96G049 96G052 96G056

96G061 G3-A-ACNC-8L0A00-LD000000 96G187 G3-G-ACNC-8LFA00-0D00L000

G3-G-ACNC-8L0000-0D000000 G3-G-12NC-8L0A00-L0C00000 G3-G-24NC-8L0A00-L0C00000 G3-A-24NC-8L0A00-L0C00000 G3-G-ACNC-8L0A00-LD000000

Model Number

12 Liter Models

Part

Numbers

96G057 G3-G-ACNC-120A00-LD000000 96G171 G3-G-24NC-120000-00C00000

Model Number

16 Liter Models

Part

Numbers

96G058 G3-G-ACNC-160A00-LD000000 96G172 G3-G-24NC-160000-00C00000

Model Number

332291B 3

Part / Model Numbers

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

G3 - G = Identifies pump as being a G3; G = Grease G3 - A = Identifies pump as being a G3; A = Oil

Code aa: Power Source

• 12 = 12 Volts DC

• 24 = 24 Volts DC

• AC = 100 - 240 Volts AC

Code bb: Operation Control

• NC = No Controller

Code cc: Reservoir Capacity (Liters)

• 2L = 2 Liters

• 4L = 4 Liters

• 8L = 8 Liters

• 12 = 12 Liters

• 16 = 16 Liters

Code d: Follower Plate Installed

• F = Follower Plate Installed

G3 -G - NC 00 0 00 0

• 0 = No Follower Plate

Code e: Low Level Option

• A = External Low Level

• 0 = No Low Level monitoring

Code ff: Options

• 00 = No Options

Code g, h, i, j, k, m, n, p NOTE: Codes g - p relate to a specific location on the

G3 pump. See F

•C = CPC

•D = DIN

• L = Low Level

• 0 = Not populated

IG. 1 for these locations.

FIG. 1

4 332291B

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 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.

• 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.

332291B 5

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, cut 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 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. This 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

6 332291B

Installation

G3-G-24NC-2L0A00-L0C00000

Grease Models with Follower Plate

96GXXX

Oil Models

Grease Models

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. This product is equipped with a cord having an equipment grounding conductor. The wire with insulation having an outer surface that is green with or without yellow stripes is the grounding wire.

Component Identification

FIG. 2:

Key:

AReservoir B Adjustable Pump Element (1 included. Can accommodate 3

total)

C Pressure Relief Valve (Not included / required for each outlet

- Available from Graco. See Parts, page 30.) 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

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

332291B 7

output volume per stroke) (also see F

from Graco. See Parts, page 30.)

H Power / Sensor Panel (both sides; only one side shown) I Part Number / Model Number example only shown, (see

page 4, Understanding the Model Number, for details)

grease models)

available on all grease models)

IG. 13, page 19)

J Power Cord (DIN shown) K Follower Plate (grease models only / not available on all

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

M Fill cap (oil models only)

Installation

Typical Installation

Divider Installations

Injector Installations

A Connected to fuse / power B Pressure relief valve (Not included/ required for each outlet -

user supplied. See Parts, page 30)

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 31.)

H Return to reservoir

8 332291B

Installation

Choosing an Installation Location

AUTOMATIC SYSTEM ACTIVATION HAZARD

If the system is equipped with has an automatic timer (user supplied) that activates the pump lubrication system when power is connected or when exiting the programming function, unexpected activation of the system could result in serious injury, including skin injection and amputation.

Before you install or remove the lubrication pump from the system, disconnect and isolate all power supplies and relieve all pressure.

• Select a location that will adequately support

the weight of the G3 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 installation patterns to use for mounting the G3. No other installation configurations should be used.

• Use designated mounting holes and provided

configurations only.

• Always mount the G3 oil models upright.

• If the G3 grease model is going to be operated in a tilted or inverted position for any period of time, you must use a model that includes a follower plate, otherwise the G3 must be mounted upright. Refer to your model number to confirm if a follower plate was installed on your pump. See page 4, Understanding the Model Number to identify this character in your model number.

• Use the three fasteners (included) to secure the G3 to the mounting surface.

• Some installations may require an additional reservoir support bracket. Consult your Graco distributor for assistance with this installation.

332291B 9

Installation

System Configuration and Wiring

Fuses

Improper installation of the grounding conductor may result in a risk of electric shock. This product must be installed by a qualified electrician in compliance with all state and local codes and regulations.

If the product is permanently connected:

• it must be installed by a qualified electrician or serviceman.

• it must be connected to a grounded, permanent wiring system.

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

• it must be rated for the product electrical specifications.

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

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

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

NOTICE

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

• Never operate G3 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.

Input Voltage

12 VDC 7.5 A 571039 24 VDC

Fuse Value

4 A

Graco Kit No.

571040

Recommendations for Using Pump in Harsh Environments

• Use pump with CPC style power cable.

• If using a DIN style power or alarm harness with a right angle mating connector, make sure the connector does not exit the unit in the UP direction.

• Use a corrosion preventative electrical grease on all contacts.

10 332291B

Installation

Wiring and Installation Diagrams

The following Table identifies the wiring and installation diagrams for the cable included with the pump provided in this manual.

Diagram

Power DIN AC 12

Power DIN DC 13

Power CPC DC 14

Low Level Outputs 15

Symbol

Page #

332291B 11

+ 23 hidden pages