Graco G3 Pro Instructions Manual

Instructions

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

3132066

G3 Pro Automatic

332298E

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) Pump Output Pressure
5000 psi (34.4 MPa, 344.7 bar) Fill Inlet Pressure

EN

Important Safety Instructions

Read all warnings and instructions in this
manual. Save all instructions.

Table of Contents

Table of 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

Typical Installation - With Remote Fill Manifold . . 9
Optional Installation -

Without Remote Fill Manifold . . . . . . . . . . . 10

Choosing an Installation Location . . . . . . . . . . . 11

System Configuration and Wiring . . . . . . . . . . . 12

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Connecting to Auxiliary Fittings . . . . . . . . . . . . . 17

Setting Pump Outlet Volume . . . . . . . . . . . . . . . 18

Loading Grease . . . . . . . . . . . . . . . . . . . . . . . . 18

Auto-Fill Shut Off . . . . . . . . . . . . . . . . . . . . . . . . 20

Filling Oil Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Quick Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . 24

Pro Model Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Control Panel Overview . . . . . . . . . . . . . . . . . . 25

Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Advanced Programming . . . . . . . . . . . . . . . . . . . . 29

Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Fault / Warning Scenarios . . . . . . . . . . . . . . . . . 33

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Parts - 2 Liter Models . . . . . . . . . . . . . . . . . . . . . . 36

Parts - 4 Liter and Larger Models . . . . . . . . . . . . . 37

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Mounting Pattern . . . . . . . . . . . . . . . . . . . . . . . . 42

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 44

Graco Information . . . . . . . . . . . . . . . . . . . . . . . 44

2 332298E

Part / Model Numbers

Part / Model Numbers

The Part Number is a six-digit unique number that is o nly us ed t o orde r t h e G3 Pum p. 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

96G011 G3-G-24PR-2L0L00-R0C00000
96G012 G3-G-24PR-2LFL00-R0C00000
96G013 G3-G-ACPR-2L0L00-0D000000
96G014 G3-G-ACPR-2LFL00-0D000000
96G027 G3-G-12PR-2L0000-00C00000
96G028 G3-G-24PR-2L0000-00C00000
96G029 G3-G-ACPR-2L0000-0D000000
96G033 G3-G-12PR-2L0L05-00C00000
96G034 G3-G-24PR-2L0L05-00C00000
96G070 G3-A-24PR-2L0L00-R0C00000
96G079 G3-A-ACPR-2L0L00-0D000000

Model Numbers

4 Liter Models

Part

Numbers

96G068 G3-G-24PR-4L0L00-R0C00000
96G071 G3-A-24PR-4L0L00-R0C00000
96G073 G3-G-24PR-4LFL00-R0C00000
96G075 G3-G-ACPR-4L0L00-0D000000
96G080 G3-A-ACPR-4L0L00-0D000000
96G082 G3-G-ACPR-4LFL00-0D000000
96G135 G3-G-12PR-4L0000-00C00000
96G137 G3-G-24PR-4L0000-00C00000
96G139 G3-G-ACPR-4L0000-0D000000
96G147 G3-G-12PR-4L0L05-00C00000
96G149 G3-G-24PR-4L0L05-00C00000
96G211 G3-G-24PR-4LAL05-00C00000

Model Numbers

8 Liter Models

Part

Numbers

96G069 G3-G-24PR-8L0L00-R0C00000
96G072 G3-A-24PR-8L0L00-R0C00000
96G076 G3-G-ACPR-8L0L00-0D000000
96G081 G3-A-ACPR-8L0L00-0D000000
96G136 G3-G-12PR-8L0000-00C00000
96G138 G3-G-24PR-8L0000-00C00000
96G140 G3-G-ACPR-8L0000-0D000000
96G148 G3-G-12PR-8L0L05-00C00000
96G150 G3-G-24PR-8L0L05-00C00000
96G208 G3-G-ACPR-8LAL00-0D00000
96G214 G3-G-24PR-8LAL05-00C00000

Model Numbers

12 Liter Models

Part

Numbers

96G077 G3-G-ACPR-120L00-0D000000
96G163 G3-G-24PR-120L05-00C00000

Model Numbers

16 Liter Models

Part

Numbers

96G078 G3-G-ACPR-160L00-0D000000
96G167 G3-G-24PR-160L05-00C00000

Model Numbers

332298E 3

Part / Model Numbers

k

m

n

p

h

j

i

g

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: Some pump configur ations are n ot a v ailable. Contact Graco Cu stomer Service or your local Gr aco distrib utor
for assistance.

G3 -G- PR 0 00 0

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

• PR = Pro (Timer) Control

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

• 0 = No Follower Plate

• A - Auto-Fill Shut Off

Code e: Low Level Option

• L = Low Level with Controller

• 0 = No Low Level monitoring

Code ff: Options

• 00 = No Options

• 05 = 5 Pin CPC power cable

• 07 = No Power Cord

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

• R = Remote Manual Run

• 0 = Not populated

IG. 1 for these locations.

FIG. 1

4 332298E

Warnings

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of t his equipment. The exclama­tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual or on warning labels, ref er bac k to these W arnings. Produ ct-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.

• T urn 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 compa tible with equipment wetted parts. See T echnical 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 mo difications ma y void agency a pprov als 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 info rmation.

• 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.

332298E 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 surgi-

cal 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 Pr ocedure when y ou stop dispensing and bef ore clean ing, 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 deg rade plastic parts and cause them to fail, which could cause serious injury or

property damage.

• Use only compatible water-based solv ents 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 cov ers 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 manuf ac­turer

6 332298E

Installation

A

D

H

I

B

E

F

J

G3-G-24PR-2LFL00-R0C00000

Grease Models with Follower

Plate

L

M

96GXXX

Oil Models

N

Grease Models

R

Auto-Fill Shut Off Models

Component Identification

Installation

FIG. 2:
Key:

A Reservoir
B Pump Element (1 included. Can accommodate 3 total)
C Pressure Relief Valve (Not included / required for each

outlet - Available from Graco. See Parts, page 40.)
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.
H Control Panel

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

K Power Cord (DIN shown)

output volume per stroke) (also see F

Availab le from Graco. See Parts, page 39.)

IG. 15, page 18)

pages 4, Understanding the Model Number, for details)

L Follower Plate (grease models only / not availabl e on al l
M Vent Hole for Follower Plate (grease models only / not
N Fill cap (oil models only)

R Auto-Fill Shut Off

grease models)
available on all grease models)

332298E 7

Installation

A

B

C

D

Typical Installation

Series Progressive Divider Valve Installations

FIG. 3

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

- user supplied. See Parts, page 40)
C Series progressive divider valves (Divider Installations)
D To lube points

8 332298E

Installation

E

D

C

F

P

N

K

H

J

M

L

A

R

Q

B

S

T

Typical Installation - With Remote Fill Manifold

The installation shown is only a guide for selecting and installing system components. Contact your Graco distributor
for assistance in planning a system to suit your needs.

FIG. 4
Key:

AG3 Pump
B Auto-Fill Shut Off Valve
C Auto-Fill Inlet
D G3 Reservoir
E Remote Fill Reservoir
F Remote Fill Pump
G Supply Hose (user supplied)
H Air Supply to Refill Pump
J Supply Hose (user supplied)
K Pressure Relief Valve
L Drain Hose
M Fill Coupler/Inlet (quick disconnect)
N Fill Manifold
P Fill Manifold Outlet
Q Fill Manifold Vent Port
R Pressure Gauge
S Pressure Regulator and Gauge
T Pressure Relief Knob

 To relieve the stall pressure in the fill line a fill manifold
(N) must be installed in the system.

332298E 9

Installation

E

F

J

S

B

C

D

A

L1

H

U

V

L

L2

W

Y

Optional Installation - Without Remote Fill Manifold

The installation shown is only a guide for selecting and installing system components. Contact your Graco distributor
for assistance in planning a system to suit your needs.

NOTE: The remote filling station pump stalls (dead-heads) when the reservoir is full. If the pump does not stall
(dead-head) there is a leak in the system.

FIG. 5
Key:

AG3 Pump
B Auto-Fill Shut Off Valve
C Auto-Fill Inlet
D G3 Reservoir
E Remote Fill Reservoir
F Remote Fill Pump
HRelief Valve
J Supply Hose (user supplied)
LDrain Tube

L1 Option - To reservoir
L2 Option - To overflow container

S Pressure Regulator and Gauge
U Pressure Relief Valve
V Quick Disconnect
W Overflow Container
Y Supply Hose Pressure Relief Valve

 To relieve the stall pressure in the fill line a ball valve
(Y) must be installed in the system.

10 332298E

Choosing an Installation Location

AUTOMATIC SYSTEM ACTIVATION HAZARD

If the system is equipped with has an auto matic 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 pu mp
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 mounting hole layouts provided in
the Mounting Pattern section of this manual,
page 42. No other installation configuration
should be used.

Installation

• Use designated mounting holes and pr ovided
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 faste ners (included) to secure t he
G3 to the mounting surface.

• Some installations may require an additional
reservoir support bracket. See Table below for
bracket information

Part No Description

571159 Reservoir bracket and strap
125910 L-Bracket for pump
127665 USP to G-Series mounting bracket

332298E 11

Installation

System Configuration and Wiring

Grounding

The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides an escape wire for the electric
current.

Improper installation of the groundin g 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 qualif ied 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.

Fuses

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 v oltage must be in stalled in
line with the power entry to the system.

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

Input Voltage

12 VDC
24 VDC

Fuse Value

7.5 A
4 A

Graco Kit No.

571039
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 prev entat iv e electrical grease on all
contacts.

• 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.

12 332298E

Installation

Remote Illumination Response

The following tab les include g raphica l representations of the connector as it appear s on the unit, a pin-out a ssociated
with the connector and a typical installation wiring diagram. An internal representative wiring diagram is included
where it is deemed useful.

Wire colors provided on these pages only refer to the power cable provided by Graco with this product.

Standard Remote Illumination

(via 5 wire CPC power cable)
Unit in OFF Mode Off Off
Unit in ON Mode On Green
Warning Condition Toggles On and Off once per second Yellow
Fault Condition Toggles On and Off once per second Red

Tri-Color Remote Illumination

Wiring and Installation Diagrams

The following Table identifies the wiring and installation diagrams provided in this manual.

Diagram Symbol Page #

Power DIN AC 14

Power DIN DC 14

Power CPC DC 15

Illuminated Manual Run Input

Kits: 571030, 571031,
571032, 571033

(M12 Connector)

332298E 13

Installation

Power DIN AC - 15 foot

Pin and Related Wire Color (FIG. 6)

Pin Pin Name Color

1 Line Black
2Neutral White
3 Not Used Not Used

4

Ground Green

Power DIN DC - 15 Foot

Pin and Related Wire Color (FIG. 7)

Pin Pin Name Color

1-VDC Black
2+VDC White
3 Not Used Not Used

4

Not Used Green

FIG. 6

14 332298E

FIG. 7