Graco G3 Pro User manual

332298E
EN
Instructions
G3 Pro Automatic
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
Important Safety Instructions
Read all warnings and instructions in this
manual. Save all instructions.
ConformstoANSI/UL73
Certified to CAN/CSA
Std. 22.2 No 68-09
3132066

Table of Contents
2332298E
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

Part / Model Numbers
332298E 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 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 its related Model
Number.
2 Liter Models
4 Liter Models
8 Liter Models
12 Liter Models
16 Liter Models
Part
Numbers Model 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
Part
Numbers Model 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
Part
Numbers Model 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
Part
Numbers Model Numbers
96G077 G3-G-ACPR-120L00-0D000000
96G163 G3-G-24PR-120L05-00C00000
Part
Numbers Model Numbers
96G078 G3-G-ACPR-160L00-0D000000
96G167 G3-G-24PR-160L05-00C00000

Part / Model Numbers
4332298E
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
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 FIG. 1 for these locations.
•C=CPC
•D=DIN
• R = Remote Manual Run
• 0 = Not populated
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
FIG. 1
k
m
np
h
j
i
g

Warnings
332298E 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-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 offanddisconnectpoweratmainswitchbeforedisconnectinganycablesandbeforeservicing
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 reg-
ulations.
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 man-
ufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may voidagency approvals and cre-
ate 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
6332298E
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 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 equip-
ment, 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, includ-
ing 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 manufac-
turer
WARNING

Installation
332298E 7
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 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
output volume per stroke) (also see FIG. 15, page 18)
G Fuse (DC models only - Not included, not shown.
Available from Graco. See Parts, page 39.)
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 (DIN 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)
R Auto-Fill Shut Off
FIG. 2:
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

Installation
8332298E
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 40)
C Series progressive divider valves (Divider Installations)
D To lube points
FIG. 3
A
B
C
D

Installation
332298E 9
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:
AG3Pump
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.
FIG. 4
E
D
C
F
P
N
K
HJ
M
LA
R
Q
B
ST

Installation
10 332298E
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.
Key:
AG3Pump
B Auto-Fill Shut Off Valve
C Auto-Fill Inlet
D G3 Reservoir
E Remote Fill Reservoir
F Remote Fill Pump
HReliefValve
J Supply Hose (user supplied)
LDrainTube
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.
FIG. 5
E
F
J
S
B
C
D
A
L1
HU
V
L
L2
W
Y