Graco G3 Series User manual

Instructions
G3 Automatic
Lubrication Pump 3A0414B
For dispensing of NLGI Grades #000 to #2 greases.
Not approved for use in European explosive atmospheres. For Professional Use Only.
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.
ENG

Table of Contents
23A0414B
Table of Contents
Part / Model Numbers - 2 Liter Models . . . . . . . . . 3
No Control Models . . . . . . . . . . . . . . . . . . . . . . . 3
Pro Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Max Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Understanding the Model Number . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 8
Choosing an Installation Location . . . . . . . . . . . . 9
System Configuration and Wiring . . . . . . . . . . . 10
Cable Wiring Diagrams . . . . . . . . . . . . . . . . . . . 20
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Connecting to Auxiliary Fittings . . . . . . . . . . . . . 24
Setting Pump Outlet Volume . . . . . . . . . . . . . . . 25
Loading Grease . . . . . . . . . . . . . . . . . . . . . . . . 26
Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Changing Greases . . . . . . . . . . . . . . . . . . . . . . 27
No Controller Operation . . . . . . . . . . . . . . . . . . . . 28
Quick Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . 29
Pro Model Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Control Panel Overview . . . . . . . . . . . . . . . . . . 30
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Max Model Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Control Panel Overview . . . . . . . . . . . . . . . . . . 34
Programming the Max Model . . . . . . . . . . . . . . 35
Pump OFF / REST Setup . . . . . . . . . . . . . . . . . 38
Advanced Programming . . . . . . . . . . . . . . . . . . . . 40
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Fault / Warning Scenarios . . . . . . . . . . . . . . . . . 47
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Mounting Pattern . . . . . . . . . . . . . . . . . . . . . . . . 59
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 60

Part / Model Numbers - 2 Liter Models
3A0414B 3
Part / Model Numbers - 2 Liter Models
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 spe-
cific 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 it’s related Model
Number.
No Control Models
Pro Models
Max Models
Part
Numbers. Model Number
96G000 G3-G-12NC-2L0000-00C00000
96G001 G3-G-24NC-2L0000-00C00000
96G002 G3-G-ACNC-2L0000-0D000000
96G003 G3-G-12NC-2L0A00-L0C00000
96G004 G3-G-12NC-2LFA00-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
Part
Numbers Model Numbers
96G009 G3-G-12PR-2L0L00-R0C00000
96G010 G3-G-12PR-2LFL00-R0C00000
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
Part
Numbers Model Numbers
96G015 G3-G-12MX-2L0L00-10CV0000
96G016 G3-G-12MX-2LFL00-10CV0000
96G017 G3-G-24MX-2L0L00-10CV00R0
96G018 G3-G-24MX-2LFL00-10CV00R0
96G019 G3-G-ACMX-2L0L00-1D0V0000
96G020 G3-G-ACMX-2LFL00-1D0V0000
96G021 G3-G-12MX-2L0L00-1DMVA2R3
96G022 G3-G-12MX-2LFL00-1DMVA2R3
96G023 G3-G-24MX-2L0L00-1DMVA2R3
96G024 G3-G-24MX-2LFL00-1DMVA2R3
96G025 G3-G-ACMX-2L0L00-1DMVA2R3
96G026 G3-G-ACMX-2LFL00-1DMVA2R3
96G030 G3-G-12MX-2L0L00-10C00000
96G031 G3-G-24MX-2L0L00-10C000R0
96G032 G3-G-ACMX-2L0L00-1D000000

Part / Model Numbers - 2 Liter Models
43A0414B
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 = Identifies pump as being a G3. G = Grease
Code a: Power Source
• 12 = 12 Volt
• 24 = 24 Volt
•AC=AC
Code b: Operation Control
• NC = No Controller
• PR = Pro (Timer) Control
• MX = Max (Cycle) Control
Code c: Reservoir Capacity (Liters)
• 2L = 2 Liters
Code d: Follower Plate Installed
• F = Follower Plate Installed
• 0 = No Follower Plate
Code e: Low Level Option
• L = Low Level with Controller
• A = External Low Level
• 0 = No Low Level monitoring
Code f: Always 00 - Available for future configuration
Code g, h, i, j, k, m, n, p
NOTE: Codes g - p relate to a specific location on the
G3 pump. See FIG. 1 for these locations.
•C=CPC
•D=DIN
• 1, 2, 3 = Sensor Number
• R = Remote Manual Run
• M = Machine Count
• A = Alarm Output
• L = Low Level
•V=VentValve
• 0 = Not populated
Code Sample: G3 -G- aabb - ccde f f - gh i j kmn p
FIG. 1
g
h
i
j
k
m
n
p

Warnings
3A0414B 5
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 symbol refers to procedure-specific risk. When
these symbols appear in the body of this manual, refer back to these warnings. Additional, product-specific warnings
may be found 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
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 manu-
facturer’s replacement parts only.
• Do not alter or modify equipment.
• 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.
SKIN INJECTION HAZARD
High-pressure fluid from dispense 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 treat-
ment.
• Do not point dispense 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 Pressure Relief Procedure in this manual, 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.

Warnings
63A0414B
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, inhala-
tion 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.
WARNING

Installation
3A0414B 7
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
Key:
A Reservoir
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 53.)
D Zerk Inlet Fill Fitting (1 included)
E Pump Outlet Plug (2 included)
F Volume Control Spacers (2 included. More spacers = less
output volume per stroke) (also see FIG. 4, page 25)
G Fuse (DC models only - Not included, not shown.
Available from Graco. See Parts, page 54.)
H Control Panel (Pro and Max models only)
I Power / Sensor Panel (both sides; only one side shown)
J Part Number / Model Number example only shown, (see
pages 3 and 4, Understanding the Model Number, for
details)
K Power Cord (DIN shown)
L Follower Plate (not included on all models)
M Vent Hole for Follower Plate (not on all models)
FIG. 2:
A
D
H
I
B
E
C
K
F
J
G3-G-24NC-2L0A00-L0C00000
Models with Follower Plate View
L
M
96GXXX

Installation
83A0414B
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 53)
C - Cycle indicator sensor cable (Divider Installations)
- Pressure switch cable (Injector Installations)
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
H Return to reservoir
A
B
C
D
E
F
A
B
D
E
C
F
H
G

Installation
3A0414B 9
Choosing an Installation Location
• 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 59.
NOTE: The two mounting hole layouts provided
in the Technical Data section show the only cor-
rect 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 upright.
• If the G3 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.
Refer to your model number to confirm if a fol-
lower 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.
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.

Installation
10 3A0414B
System Configuration and Wiring
If the product is permanently connected:
• it must be installed by a qualified electrician or ser-
viceman.
• it must be connected to a grounded,permenent 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.
• when repair or replacement of the power cord or
plug is required, do not connect the grounding wire
to either flat blade terminal.
Fuses
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.
• If using a DIN style power or alarm harness with a
right angle mating connector, make sure the con-
nector does not exit the unit in the UP direction.
• Use a corrosion preventative electrical grease on all
contacts.
.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.
NOTICE
Fuses (user supplied) are required on all DC mod-
els. 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.
Input Voltage Fuse Value Graco Kit No.
12 VDC 7.5 A 571039
24 VDC 4 A 571040

Installation
3A0414B 11
Alarm Output and Remote Illumination Response
The following tables include graphical representations of the connector as it appears on the unit, a pin-out associated
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.
Alarm Relay Response
Alarm Output
Standard Remote
Illumination
(via 5 wire CPC power
cable - Kit 571049)
Tri-Color Remote
Illumination
(via illuminated manual run
input)
Unit in OFF Mode Deactivated (off) Off Off
Unit in ON Mode Deactivated (off) On Green
Warning Condition Activated (on) Toggles On and Off once
per second Yellow
Fault Condition Toggles On and Off
once per second
Toggles On and Off once
per second Red
Output Tied to Common
No Faults or
Warnings
Warning
Fault
N.O.
N.C.
N.O.
N.C.
N.O.
N.C.
1 second

Installation
12 3A0414B
Wiring and Installation Diagrams
The following Table identifies the wiring and installation diagrams provided in this manual. Additional wiring diagrams
for power cords and cables (described on the parts list, page 53) start on page 57.
Diagram Symbol Page #
Power DIN AC 13
Power DIN DC 14
Power CPC DC 15
Inputs 16
Vent Valve Outputs 17
Alarm Outputs 18
Low Level Outputs 19
Illuminated Manual Run Input Kits: 571030, 571031,
571032, 571033

Installation
3A0414B 13
Power DIN AC
1 LINE
2 NEUTRAL
3 Not Used
4 GROUND
Black
White
Not Used
Green/Yellow
(2)
(4)
(1)
(3)
1
2
3
4
Black
White
Green/Yellow
Example Wiring Diagram
Pin-out (AC)Connector on Housing

Installation
14 3A0414B
Power DIN DC
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.
1-VDC
2+VDC
3Not Used
4Not Used
Black
White
Not Used
Green
(1)
(4)
(2)
(3)
Ignition Switch
Fuse
1
2
3
4
Example Wiring Diagram
Pin-out (DC)Connector on Housing
12V-pump - 7.5A
24V pump - 4A

Installation
3A0414B 15
Power CPC DC
1Not Used
2- VDC
3+ VDC
4Not Used
Not Used
Black
White
Not Used
5 Not Used
6 Not Used
7 Not Used
Not Used
Not Used
Green/Yellow
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Example Wiring Diagram
Pin-outConnector on Housing
Ignition Switch
Fuse
1
2
3
4
5
6
7
12V-pump - 7.5A
24V pump - 4A

Installation
16 3A0414B
Inputs
1 SW +
2 Not Used
3 SW -
4 Signal
(2)
(3)
(4)
(1)
Sink (NPN) 2 or 3 wire
1
2
3
4
Source (PNP) 2 or 3 wire
1
2
3
4
Dry Contacts
1
2
3
4
Example Wiring Diagram
Pin-outConnector on Housing

Installation
3A0414B 17
Vent Valve Outputs
See Technical Data, page 57 for ratings.
(1)
(2)
(3)
1 Not Used
2 Relief+
3 Relief -
1
2
3
Example Wiring Diagram
Pin-outConnector on Housing

Installation
18 3A0414B
Alarm Outputs
DC example shown. See Alarm Outputs, page 18 for functional description of alarm output. See Technical
Data, page 57 for ratings.
1 N.O.
2 N.C.
3 COM
4 Not Used
(1)
(4)
(2)
(3)
1
2
3
4
G3
Switch closes on alarm
(shown in non-alarmposition)
Alarm+9-30V
1 Amp Max
1 A Fuse
Example Wiring Diagram
Pin-outConnector on Housing

Installation
3A0414B 19
Low Level Outputs
See Low Level Output Option, page 28 for functional description.
1
2
3
4
G3
Example Wiring Diagram

Installation
20 3A0414B
Cable Wiring Diagrams
Part No. 123749: 3-Wire
1Not Used
2- VDC
3+ VDC
4Not Used
Not Used
Black
White
Not Used
5 Not Used
6 Not Used
7 Not Used
Not Used
Not Used
Green/Yellow
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Example Wiring Diagram
Pin-outConnector on Housing
Ignition Switch
Fuse
1
2
3
4
5
6
7
12V-pump - 7.5A
24V pump - 4A