Graco G3 Series, 96G502, 96G501, 96G503, 96G500 Instructions Manual

Instructions

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

3132066

24V and 110-240VAC Pumps ONLY

G3 Standard Automatic
Lubrication Pump

For dispensing of NLGI Grades #000 to #2 greases. For Professional Use Only.

Not approved for use in explosive atmospheres or hazardous locations.

5100 psi (35.1 MPa, 351.6 bar) Maximum Pump Output Pressure
5000 psi (34.4 MPA, 344.7 bar) Maximum Fill Inlet Pressure

Important Safety Instructions

Read all warnings and instructions in this
manual before using this equipment. Save
these instructions.

3A6319A

EN

Part / Model Numbers

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

8 Liter Models

Part Model Numbers

96G500

12 Liter Models

Part Model Numbers

96G501 G3-G-24NC-12TA00-0D00L000

G3-G-24NC-8LTA00-0D00L000

16 Liter Models

Part Model Numbers

96G502 G3-G-24NC-16TA00-0D00L000

20 Liter Models

Part Model Numbers

96G503 G3-G-24NC-20TA00-0D00L000

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Part / Model Numbers

k

h

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 configurations are not available. Contact Graco Customer Service or your local Graco distributor
for assistance.

G3 -G - NC

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

• 24 = 24 Volts DC

Code bb: Operation Control

• NC = No Controller

Code cc: Reservoir Capacity (Liters)

• 8L = 8 Liters

• 12 = 12 Liters

• 16 = 16 Liters

• 20 = 20 Liters

Code d: Follower Plate Installed

• T = Follower Plate Installed; Tie Rods

Code e: Low Level Option

• A = Low Level No Controller

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

•D = DIN

• 0 = Not populated

• L = Low Level

IG. 1 for these locations.

FIG. 1

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Warnings

WARNING

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.

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.

• A pressure relief valve is required at each pump outlet.

• Follow the Pressure Relief Procedure in this manual before servicing.

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Warnings

WARNING

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.

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.

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.

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Installation

A

B

D

E

F

H

J

K

L

M

N

Installation

Component Identification - 8 Liter Model Shown

See Parts, page 17 for expanded view.

FIG. 2

Key:

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

each outlet - Available from Graco. See Parts, page 18.)
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 F
G Fuse (DC models only - Not included, not shown. Available

from Graco. See Parts, page 18.)
HCover

J Top Mounting Bracket

IG. 9, page 12)

K Bottom Mounting Bracket

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

pages 3, Understanding the Model Number, for details)
M Follower Plate
N Vent Hole for Follower Plate

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Typical Installation

A

B

D

E

F

C

Series Progressive Divider Valve

Installation

FIG. 3

Key

A Connected to fused power source
B Pressure relief valve (Not included; required for each out-

let - user supplied)

C Supply Hose (user supplied)

D Series progressive divider valves
E To lube points
F Proximity Switch

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