Graco G3 Series User manual

3A6319A
EN
Instructions
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.
Conforms to ANSI/UL 73
Certified to CAN/CSA
Std. 22.2 No 68-09
3132066
24V and 110-240VAC Pumps ONLY

Part / Model Numbers
23A6319A
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 3. The tables below shows the relationship between each Part Number and its related Model
Number.
8 Liter Models
12 Liter Models
16 Liter Models
20 Liter Models
Part Model Numbers
96G500 G3-G-24NC-8LTA00-0D00L000
Part Model Numbers
96G501 G3-G-24NC-12TA00-0D00L000
Part Model Numbers
96G502 G3-G-24NC-16TA00-0D00L000
Part Model Numbers
96G503 G3-G-24NC-20TA00-0D00L000

Part / Model Numbers
3A6319A 3
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
• 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 FIG. 1 for these locations.
•D=DIN
• 0 = Not populated
• L = Low Level
G3 -G- NC
Code Sample: a a b b - c c d e f f - g h i j k m n p
FIG. 1
k
h

Warnings
43A6319A
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
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.

Warnings
3A6319A 5
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.
•SeeTechnical 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.

Installation
63A6319A
Installation
Component Identification - 8 Liter Model Shown
See Parts, page 17 for expanded view.
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 FIG. 9, page 12)
G Fuse (DC models only - Not included, not shown. Available
from Graco. See Parts, page 18.)
HCover
J Top Mounting Bracket
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
FIG. 2
A
B
DE
F
H
J
K
L
M
N

Installation
3A6319A 7
Typical Installation
Series Progressive Divider Valve
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
FIG. 3
A
B
D
E
F
C

Installation
83A6319A
Injector Installations
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)
DInjectors
E To lube points
F Pressure switch
G Vent valve (Not included / available from Graco)
H Return to reservoir
FIG. 4
A
B
D
E
F
H
G
C

Installation
3A6319A 9
Unpacking
The pump module was carefully packaged for shipment
by Graco. When the package arrives, perform the follow-
ing procedure to unpack the units:
1. Inspect the shipping box carefully for shipping
damage. Contact the carrier promptly if damage is
discovered.
2. Unseal the box and inspect the contents carefully.
There should not be any damaged parts.
3. Compare the packing slip against all items included
in the box. Any shortages or other inspection
problems should be reported immediately.
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 mounting hole layouts provided in
the Mounting Bracket Dimensions section of this
manual, page 21. No other installation configu-
ration should be used.
- Use designated mounting holes and provided
configurations only.
- Use the five fasteners (included) to secure the
G3 to the mounting surface. 3 fasteners are
used for the bottom bracket and 2 fasteners are
used for the top bracket.
- Adjust top mounting bracket, if necessary to
align the bracket with the mounting surface (FIG.
5).
- Insert (user supplied) spacers if there is still a
gap after adjusting the bracket.
System Wiring
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
• 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.
NOTICE
Observe precautions for handling electrostatic sensi-
tive devices. Touch ground before handling pump.
AUTOMATIC SYSTEM ACTIVATION HAZARD
If the system is equipped with has an automatic timer
(user supplied) that activates the pump lubrication
system when power is connected or when exiting the
programming function, unexpected activation of the
system could result in serious injury, including skin
injection and amputation.
Before you install or remove the lubrication pump
from the system, disconnect and isolate all power
supplies and relieve all pressure.
FIG. 5
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.
24 VDC 4 A 571040

Installation
10 3A6319A
Wiring and Installation Diagrams
The following Table identifies the wiring and installation
diagrams for the cable included with the pump provided
in this manual.
Power DIN DC - 15 foot
Pin and Related Wire Color (FIG. 6)
Low Level Outputs
See Low Level Output Option, page 14 for functional
description. See Technical Specifications, page 20 for
ratings.
Pins (FIG. 7)
Pin Pin Name Color
1-VDC Black
2+VDC White
3 Not Used Not Used
4Not Used Green
FIG. 6
Pin Pin Name
1 LL N.O.
2 Not Used
3LLCOM
4 Not Used
FIG. 7