Graco G3 Pro User manual

332298J
EN
Instructions
G3™ Pro Automatic
Lubrication Pump
For dispensing 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 (classified) 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
Important Safety Instructions
Read all warnings and instructions in this
manual. Save all instructions.
Conforms to ANSI/UL 73
Certified to CAN/CSA
C22.2 No 68
3132066
24V and 100-240VAC Pumps ONLY

Table of Contents
2 332298J
Table of Contents
Part / Model Numbers . . . . . . . . . . . . . . . . . . . . . . . 3
2 Liter ModelsG3 . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 9
Typical Installation - With Remote Fill Manifold 10
Optional Installation - Without Remote
Fill Manifold . . . . . . . . . . . . . . . . . . . . . . . . 11
Choosing an Installation Location . . . . . . . . . . . 12
System Configuration and Wiring . . . . . . . . . . . 13
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Connecting to Auxiliary Fittings . . . . . . . . . . . . 17
Setting Pump Outlet Volume . . . . . . . . . . . . . . 18
Loading Grease . . . . . . . . . . . . . . . . . . . . . . . . . 18
Auto-Fill Shut Off . . . . . . . . . . . . . . . . . . . . . . . 21
Fill Oil Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Prime the Pump . . . . . . . . . . . . . . . . . . . . . . . . 24
Quick Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . . 25
Pro Model Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Control Panel Overview (FIG. 24) . . . . . . . . . . . 26
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Advanced Programming . . . . . . . . . . . . . . . . . . . . 30
Models with Firmware 6.03 and later. DMS
Models with Firmware 7.07 and later. . . . . 34
Models with Firmware 6.06 and later for
non-DMS models. Models with Firmware
7.09 and later for DMS models . . . . . . . . . 35
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fault / Warning Scenarios . . . . . . . . . . . . . . . . . 38
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Parts - 2 Liter Models . . . . . . . . . . . . . . . . . . . . . . 41
Parts - 4 Liter and Larger Models . . . . . . . . . . . . 42
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Mount Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Technical Specifications . . . . . . . . . . . . . . . . . . . . 47
California Proposition 65 . . . . . . . . . . . . . . . . . . 47
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 48

Part / Model Numbers
332298J 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 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 ModelsG3
4 Liter Models
8 Liter Models
12 Liter Models
16 Liter Models
Part
Numbers Model Number
96G011 G3-G-24PR-2L0L00-R0C00000 X
96G012 G3-G-24PR-2LFL00-R0C00000 X
96G013 G3-G-ACPR-2L0L00-0D000000 X
96G014 G3-G-ACPR-2LFL00-0D000000 X
96G027 G3-G-12PR-2L0000-00C00000
96G028 G3-G-24PR-2L0000-00C00000 X
96G029 G3-G-ACPR-2L0000-0D000000 X
96G033 G3-G-12PR-2L0L05-00C00000
96G034 G3-G-24PR-2L0L05-00C00000 X
96G070 G3-A-24PR-2L0L00-R0C00000 X
96G079 G3-A-ACPR-2L0L00-0D000000 X
96G255 G3-G-12PR-2L0L07-00C00000
96G285 G3-G-24PR-2L0007-0D000000
Part
Numbers Model Number
96G068 G3-G-24PR-4L0L00-R0C00000 X
96G071 G3-A-24PR-4L0L00-R0C00000 X
96G073 G3-G-24PR-4LFL00-R0C00000 X
96G075 G3-G-ACPR-4L0L00-0D000000 X
96G080 G3-A-ACPR-4L0L00-0D000000 X
96G082 G3-G-ACPR-4LFL00-0D000000 X
96G135 G3-G-12PR-4L0000-00C00000
96G137 G3-G-24PR-4L0000-00C00000 X
96G139 G3-G-ACPR-4L0000-0D000000 X
96G147 G3-G-12PR-4L0L05-00C00000
96G149 G3-G-24PR-4L0L05-00C00000 X
96G211 G3-G-24PR-4LAL05-00C00000 X
96G256 G3-G-24PR-4L0L07-00C00000 X
Part
Numbers Model Number
96G069 G3-G-24PR-8L0L00-R0C00000 X
96G072 G3-A-24PR-8L0L00-R0C00000 X
96G076 G3-G-ACPR-8L0L00-0D000000 X
96G081 G3-A-ACPR-8L0L00-0D000000 X
96G136 G3-G-12PR-8L0000-00C00000
96G138 G3-G-24PR-8L0000-00C00000 X
96G140 G3-G-ACPR-8L0000-0D000000 X
96G148 G3-G-12PR-8L0L05-00C00000
96G150 G3-G-24PR-8L0L05-00C00000 X
96G208 G3-G-ACPR-8LAL00-0D00000 X
96G214 G3-G-24PR-8LAL05-00C00000 X
96G257 G3-G-24PR-8L0L07-00C00000 X
96G268 G3-G-24PR-8LLL05-00C00000
96G270 G3-G-24PR-8LFL07-00C00000 X
Part
Numbers Model Number
96G077 G3-G-ACPR-120L00-0D000000 X
96G163 G3-G-24PR-120L05-00C00000 X
96G247 G3-G-24PR-120L00-R0C00000 X
Part
Numbers Model Number
96G078 G3-G-ACPR-160L00-0D000000 X
96G167 G3-G-24PR-160L05-00C00000 X

Part / Model Numbers
4 332298J
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 distribu-
tor 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
•PR = Pro (Timer) Control
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
Code f: Low Level Option
•L = Low Level with Controller
•0 = No Low Level monitoring
Code gg: Options
•00 = No Options
•05 = 5 Pin CPC power cable
•07 = No Power Cord
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
•R = Remote Manual Run
•0 = Not populated
G 3 - - P R 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
m
n
pq
i
k
j
h

Warnings
332298J 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 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-spe-
cific 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 cord before servicing equipment.
• Connect only to grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on power and extension cords.
• 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 Spec-
ifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For com-
plete 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 man-
ufacturer’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
6 332298J
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
332298J 7
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
8 332298J
Installation
Component Identification
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 45.)
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. 11, page 18)
G Fuse (DC models only - Not included, not shown.
Available from Graco. See Parts, page 44.)
H Control Panel
I Power / Sensor Panel (both sides; only one side shown)
J Part Number / Model Number example only shown, (see
pages 4, Understanding the Model Number, for details)
K Power Cord (Not shown)
L Follower Plate (grease models only / not available on all
grease models)
M Vent Hole for Follower Plate (grease models only / not
available on all grease models)
N Fill cap (oil models only)
O Top Fill Lid
R Auto-Fill Shut Off
FIG. 2:
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
A
N
Top Fill Models
O

Installation
332298J 9
Typical Installation
Series Progressive Divider Valve Installations
A Connected to fused power source
B Pressure relief valve (Not included/required for each
outlet - user supplied. See Parts, page 45)
C Series progressive divider valves (Divider Installations)
D To lube points
FIG. 3
A
B
C
D

Installation
10 332298J
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.
Key:
A G3 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 mani-
fold (N) must be installed in the system.
FIG. 4
E
D
C
F
P
N
K
HJ
M
L
A
R
Q
B
S
T