Graco G3 Series User manual

Conforms to ANSI/UL 73
Certified to CAN/CSA
Std. 22.2 No 68-09
3132066
24V and 110-240VAC Pumps ONLY
332291P
EN
Instructions
G3 Standard Automatic
Lubrication Pump
For dispensing of NLGI Grades #000 to #2 greases and oils 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 (34.3 MPa, 344.8 bar) Fill Inlet Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual before using the equipment.
Save these instructions.

2 332291P
Contents
Part / Model Numbers . . . . . . . . . . . . . . . . . . . . . . . 3
2 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
12 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 4
16 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Understanding the Model Number . . . . . . . . . . . 5
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 10
Typical Installation - With Remote
Fill Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 11
Optional Installation - Without Remote
Fill Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 12
Choose an Installation Location . . . . . . . . . . . . 13
System Configuration and Wiring . . . . . . . . . . . 13
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 19
Connect to Auxiliary Fightings . . . . . . . . . . . . . . 19
Set Pump Outlet Volume . . . . . . . . . . . . . . . . . . 20
Load Pump with Grease . . . . . . . . . . . . . . . . . . 20
Auto-Fill Shut Off . . . . . . . . . . . . . . . . . . . . . . . . 23
Fill the Oil Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Prime the Pump . . . . . . . . . . . . . . . . . . . . . . . . . 26
Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Recycling and Disposal . . . . . . . . . . . . . . . . . . . . . 29
End of Product Life . . . . . . . . . . . . . . . . . . . . . . 29
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Parts - 2 Liter Models. . . . . . . . . . . . . . . . . . . . . . . 32
Parts - 4 Liter and Larger Models . . . . . . . . . . . . . 33
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Mounting Pattern . . . . . . . . . . . . . . . . . . . . . . . . 38
Technical Specifications . . . . . . . . . . . . . . . . . . . . 40
California Proposition 65 . . . . . . . . . . . . . . . . . . 41
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 42

332291P 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 Num-
ber 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 the Model Number, page 5. The
tables below shows the relationship between each Part Number and its related Model Number.
2 Liter Models 4 Liter Models
Part
Numbers Model Number
96G000 G3-G-12NC-2L0000-00C00000
96G001 G3-G-24NC-2L0000-00C00000 X
96G002 G3-G-ACNC-2L0000-0D000000 X
96G003 G3-G-12NC-2L0A00-L0C00000
96G005 G3-G-24NC-2L0A00-L0C00000 X
96G006 G3-G-24NC-2LFA00-L0C00000 X
96G007 G3-G-ACNC-2L0A00-LD000000 X
96G008 G3-G-ACNC-2LFA00-LD00000 X
96G050 G3-A-24NC-2L0A00-L0C00000 X
96G059 G3-A-ACNC-2L0A00-LD000000 X
96G182 G3-G-24NC-2L0A00-0D00L000 X
96G239 G3-G-24NC-2L0A06-00C00000 X
96G243 G3-G-24NC-2L0A00-0D00L000 X
96G261 G3-G-24NC-2L0A07-L0C00000 X
Part
Numbers Model Number
96G038 G3-G-12NC-4L0L00-00C00000
96G040 G3-G-24NC-4L0000-00C00000 X
96G042 G3-G-ACNC-4L0000-0D000000 X
96G044 G3-G-12NC-4L0A00-L0C00000
96G048 G3-G-24NC-4L0A00-L0C00000 X
96G051 G3-A-24NC-4L0A00-L0C00000 X
96G053 G3-G-24NC-4LFA00-L0C00000 X
96G055 G3-G-ACNC-4L0A00-LD000000 X
96G060 G3-A-ACNC-4L0A00-LD000000 X
96G062 G3-G-ACNC-4LFA00-LD000000 X
96G173 G3-G-ACNC-4LFA00-0D00L000 X
96G179 G3-G-ACNC-4LFA00-0D00L000 X
96G184 G3-G-24NC-4L0A00-0D00L000 X
96G210 G3-G-24NC-4LAA00-0D00L000 X
96G180 G3-G-24NC-4L0A02-L0C00000 X
96G202 G3-G-ACNC-4L0A00-0D00L000 X
96G204 G3-G-24NC-4LFA00-0D00L000 X
96G238 G3-G-24NC-4L0A06-00C00000 X
96G248 G3-G-24NC-4L0A02-L0C00000 X
96G250 G3-G-24NC-4LFA07-0D00L000 X
96G273 G3-G-12NC-4L0A10-00C00000
96G276 G3-G-24NC-4L0A07-0D00L000 X
96G277 G3-G-24NC-4LLA06-00C00000
96G278 G3-G-24NC-4LHA06-00C00000
96G280 G3-G-24NC-4LHA00-0D00L000
96G287 G3-G-24NC-4L0A10-00C00000

4 332291P
8 Liter Models 12 Liter Models
16 Liter Models
Part
Numbers Model Number
96G039 G3-G-12NC-8L0000-00C00000
96G041 G3-G-24NC-8L0000-00C00000 X
96G043 G3-G-ACNC-8L0000-0D000000 X
96G045 G3-G-12NC-8L0A00-L0C00000
96G049 G3-G-24NC-8L0A00-L0C00000 X
96G052 G3-A-24NC-8L0A00-L0C00000 X
96G056 G3-G-ACNC-8L0A00-LD000000 X
96G061 G3-A-ACNC-8L0A00-LD000000 X
96G187 G3-G-ACNC-8LFA00-0D00L000 X
96G189 G3-G-24NC-8L0A00-0D00L000 X
96G192 G3-G-24NC-8LFA00-L0C00000 X
96G198 G3-G-24NC-8L0A06-0C000000 X
96G207 G3-G-ACNC-8LAA00-LD000000 X
96G213 G3-G-24NC-8LAA00-0D00L000 X
96G217 G3-G-24NC-8LAA06-00C00000 X
96G205 G3-G-24NC-8LFA00-0D00L000 X
96G233 G3-G-12NC-8L0A00-0D00L000
96G262 G3-G-24NC-8LLA06-00C00000
96G249 G3-G-24NC-8L0A07-0D00L000 X
96G251 G3-G-24NC-8LFA07-0D00L000 X
96G271 G3-G-24NC-8LFA07-00C00000 X
96G272 G3-G-24NC-8LFA10-00C00000
96G279 G3-G-24NC-8LHA06-00C00000
96G281 G3-G-24NC-8LHA00-0D00L000
96G290 G3-G-24NC-8LAA10-00C00000
Part
Numbers Model Number
96G057 G3-G-ACNC-120A00-LD000000 X
96G171 G3-G-24NC-120000-00C00000 X
96G199 G3-G-24NC-120A00-L0C00000 X
96G240 G3-G-24NC-120A00-0D00L000 X
Part
Numbers Model Number
96G058 G3-G-ACNC-160A00-LD000000 X
96G172 G3-G-24NC-160000-00C00000 X
96G220 G3-G-24NC-160A00-L0C00000 X
96G230 G3-G-12NC-160A00-0D00000
96G237 G3-G-ACNC-16AA00-LD000000 X
96G241 G3-G-24NC-160A00-0D00L000 X
96G258 G3-A-24NC-160A00-L0C00000 X

332291P 5
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: Other pump configurations are available that are not documented in this manual. Contact Graco Customer
Service or your local Graco distributor 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
• NC = No Controller
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
• H = Hammer Pump
Code f: Low Level Option
• A = External Low Level
• 0 = No Low Level monitoring
Code gg: Options
• 00 = No Options
• 06 = Low Level in CPC
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
• L = Low Level
• 0 = Not populated
G 3 - - N C 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
p
q
i
k
j
h

Warnings
6 332291P
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.
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
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 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.

Warnings
332291P 7
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
8 332291P
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
332291P 9
Installation
Component Identification
Key:
A Reservoir
B Adjustable Pump Element (1 included. Can
accommodate 3 total)
C Pressure Relief Valve (Not included (not shown) / required
for each outlet - Available from Graco. See Parts, page
35.)
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. 18, page 20)
G Fuse (DC models only - Not included, not shown.
Available from Graco. See Parts, page 34.)
H Power / Sensor Panel (both sides; only one side shown)
I Part Number / Model Number example only shown, (see
page 5, Understanding the Model Number, for details)
J Power Cord (Not shown)
K Follower Plate (grease models only / not available on all
grease models)
L Vent Hole for Follower Plate (grease models only / not
available on all grease models)
M Fill cap (oil models only)
N Auto-Fill Shut Off
P Top Fill Lid
FIG. 2
A
D
H
E
I
G3-G-24NC-2L0A00-L0C00000
96GXXX
P
M
Grease Models
Auto-Fill Shut Off Models
N
F
B
K
L
Grease Models with
Follower Plate
Oil Models Top Fill Models

Installation
10 332291P
Typical Installation
Series Progressive Divider Valve
Injector Installations
Key
A Connected to fused power source
B Pressure relief valve (Not included/ required for each out-
let - user supplied. See Parts, page 35)
C Supply Hose (user supplied)
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 (Not included / available from Graco. See
Parts, page 36.)
H Return to reservoir
FIG. 3
FIG. 4
A
B
DE
F
C
A
B
D
E
F
H
G
C