Graco G3 SP Series User manual

3A4676B
EN
Instructions
G3 SP™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.
Part Nos., page 3
5100 psi (35.1 MPa, 351.6 bar) Pump Output Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual. Save all instructions.
Conforms to ANSI/UL 73
Certified to CAN/CSA
Std. 22.2 No 68-09
3132066
24V and 110-240VAC Pumps ONLY

23A4676B
Contents
Part / Model Numbers . . . . . . . . . . . . . . . . . . . . . . . 3
Understanding the Model Number . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 9
Choosing an Installation Location . . . . . . . . . . . 10
System Configuration and Wiring . . . . . . . . . . . 10
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Connecting to Auxiliary Fittings . . . . . . . . . . . . . 16
Setting Pump Outlet Volume . . . . . . . . . . . . . . . 17
Loading Grease . . . . . . . . . . . . . . . . . . . . . . . . 17
Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Quick Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . 19
Control Panel Overview . . . . . . . . . . . . . . . . . . 20
Programming . . . . . . . . . . . . . . . . . . . . . . . . . . 21
PUMP OFF / REST Setup . . . . . . . . . . . . . . . . 22
Advanced Programming . . . . . . . . . . . . . . . . . . . . 24
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Pump OFF / Rest Mode . . . . . . . . . . . . . . . . . . 29
Lubrication Mode: Cycle Control (Pump ON) . . 29
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fault / Warning Scenarios . . . . . . . . . . . . . . . . . 31
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Parts - 2 Liter Models . . . . . . . . . . . . . . . . . . . . . . 38
Parts - 4 Liter and Larger Models . . . . . . . . . . . . . 39
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Mounting Pattern . . . . . . . . . . . . . . . . . . . . . . . . 44
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 46
Graco Information . . . . . . . . . . . . . . . . . . . . . . . 46

Part / Model Numbers
3A4676B 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
96G221 G3-G-12SP-2L0L09-10C00000
96G223 G3-G-24SP-2L0L09-10C00000
96G227 G3-G-ACSP-2L0L00-1D00000
Part
Numbers Model Numbers
96G222 G3-G-12SP-4L0L09-10C00000
96G224 G3-G-24SP-4L0L09-10C00000
96G228 G3-G-ACSP-4L0L00-1D00000
Part
Numbers Model Numbers
96G225 G3-G-24SP-8L0L09-10C00000
Part
Numbers Model Numbers
96G226 G3-G-24SP-120L09-10C00000
Part
Numbers Model Numbers
96G245 G3-G-ACSP-160L00-1D000000

Part / Model Numbers
43A4676B
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 aa: Power Source
• 12 = 12 Volts DC
• 24 = 24 Volts DC
• AC=100-240 Volts AC
Code bb: Operation Control
• SP = Series Progressive
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
• 0 = No Follower Plate
Code e: Low Level Option
• L = Low Level with Controller
Code ff: Options
• 00=No Options
• 09 =Alarm, manual run and low level in CPC
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 = Sensor Number
• 0 = Not populated
G3-G- SP 0L 1 0000 0
Code Sample: a a b b - c c d e f f - g h i j k m n p
FIG. 1
m
n
p
i
g
j
h

Warnings
3A4676B 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 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 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 void agency 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
63A4676B
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.
WARNING

Warnings
3A4676B 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.
• 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
83A4676B
Installation
Component Identification
Key:
AReservoir
B Pump Element (1 included. Can accommodate 3 total)
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. 13, page 17)
G Fuse (DC models only - Not included, not shown. Avail-
able from Graco. See Parts, page 43.)
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)
FIG. 2:
A
D
H
I
B
E
F
J
G3-G-12SP-2L0L09-10C00000
96GXXX

Installation
3A4676B 9
Typical Installation
Series Progressive Divider Valve Installations
P Connected to fused power source
Q Pressure relief valve (Not included. Required for each
outlet - user supplied. See Parts, page 43)
R Cycle indicator sensor cable
S Series progressive divider valves
T To lube points
U Proximity Switch
FIG. 3
P
Q
R
S
T
U

Installation
10 3A4676B
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 Pattern section of this manual,
page 46. No other installation configuration
should be used.
• Use designated mounting holes and provided
configurations only.
• Use the three fasteners (included) to secure the
G3 to the mounting surface.
• Some installations may require an additional
reservoir support bracket. See Table below for
bracket information
System Configuration and
Wiring
Grounding
If the product is permanently connected:
• it must be installed by a qualified electrician or ser-
viceman.
• it must be connected to a grounded, permanent 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.
AUTOMATIC SYSTEM ACTIVATION HAZARD
The G3 system is equipped with an automatic timer
that activates the pump lubrication system. Unex-
pected activation of the system could occur and
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.
Part No Description
571159 Reservoir bracket and strap
125910 L-Bracket for pump
127665 USP to G-Series mounting bracket
The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides an escape wire for the electric
current.
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.

Installation
3A4676B 11
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.
• Use a corrosion preventative electrical grease on all
contacts.
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
12 3A4676B
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.
Stays on only for Low Level fault condition.
Wiring and Installation Diagrams
The following Table identifies the wiring and installation diagrams provided in this manual.
Outputs
(via 5 wire CPC power cable)
Pin 4
Alarm
Pin 7
Low Level
Unit in OFF Mode Off Off
Unit in ON Mode Off Off
Warning Condition Off Off
Low Level Indication
(Advanced Programming Setting A9 OFF) Off Activated (On)
Low Level Indication
(Advanced Programming Setting A9 ON) Off Toggles On and OFF once per second
Fault Condition
(Advanced Programming Setting A7 OFF)
Toggles On and Off
once per second 
Fault Condition (Advanced Programming Set-
ting A7 ON) Activated (On) 
Diagram Symbol Page #
Power DIN AC 13
Power CPC DC 13
Inputs (M12) 14

Installation
3A4676B 13
Power DIN AC - 15 foot: Part No.
16U790
Pin and Related Wire Color (FIG. 4)
Pin and Related Wire Color (FIG. 5)
Power CPC DC - 5 Wire
Part No.: 127780: 15 ft (4.5 m)
Part No.: 127781: 20 ft (6.1 m)
Part No.: 127782: 30 ft (9.1 m)
Pin Pin Name Color
1 Line Black
2 Neutral White
3 Not Used Not Used
4Ground Green
FIG. 4
CPC Pin Pin Name Wire Color
1 Not Used Not Used
2 -VDC/Com Black
3+VDC Red
4 Alarm White
5 Manual Orange
6 Not Used Not Used
7 Low Level Warning Green
FIG. 5

Installation
14 3A4676B
Inputs (M12)
See Technical Data, page 44 for ratings.
Part No. 124333: Cable Pin Out (M12) for
5 m Cable
Wire Colors (FIG. 7)
FIG. 6
1 SW +
2 Not Used
3 SW -
4 Signal
(3)
(4)
(1)
(2)
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
Item No. Color
1Brown
2White
3Blue
4Black
FIG. 7

Installation
3A4676B 15
Part No. 124300: Male Flying Lead Pin Out
(M12)
Wire Colors (FIG. 8)
Part No. 124301: 4 Pin (M12) Female Field
Wireable Connector for 6-8 mm Cable
Part No. 124594: 4 Pin (M12) Male Field
Wireable Connector for 6-8 mm Cable
NOTE: Field wireable connectors are for sensors with
integrated cable.
Part No. 124595: 5 Pin (M12) Male Field
Wireable Connector for 8-11 mm Cable
NOTE: Field wireable connectors are for sensors with
integrated cable.
Item No. Color
1Brown
2White
3Blue
4Black
FIG. 8
FIG. 9
FIG. 10
FIG. 11

Setup
16 3A4676B
Setup
Pressure Relief
Follow the Pressure Relief Procedure whenever
you see this symbol.
Relieve pressure in system using two wrenches
working in opposite directions on pump element and
pump element fitting to slowly loosen fitting only until
fitting is loose and no more lubricant or air is leaking
from fitting.
NOTE: When loosening pump element fitting, do NOT
loosen pump element. Loosening pump element will
change the output volume.
Connecting to Auxiliary Fittings
Pressure Relief Valves
NOTE: A pressure relief valve can be purchased from
Graco. See Parts, page 43.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop dispensing and before
cleaning, checking, or servicing the equipment.
FIG. 12
NOTICE
Do not attach unsupported equipment to auxiliary fit-
tings such as fill ports and pump element. Attaching
unsupported equipment to these fitting can result in
irreparable housing damage.
• Always use two wrenches working in opposite
directions when connecting anything to pump ele-
ment or auxiliary fittings. See FIG. 12 for an exam-
ple.
• Torque pump element fittings to 50 in. lbs (5.6
N•m).
• When connecting pump element into housing
torque to 50 in. lbs (5.6 N•m).
To prevent over-pressurization, which can result in
equipment rupture and serious injury, a pressure
relief valve appropriate for the lubrication system
must be installed close to every pump outlet to allevi-
ate unintended pressure rises in the system and pro-
tect the G3 pump from damage.
• Only use a pressure relief valve that is rated for
no more than the working pressure of any com-
ponent installed in the system. See Technical
Data, page 41.
• Install a pressure relief valve close to every pump
outlet; before any auxiliary fitting.

Setup
3A4676B 17
Setting Pump Outlet Volume
NOTE:
• Before making any adjustments to pump volume,
Relieve Pressure following procedure on page 16.
• Only use Graco supplied spacers to control output
volume.
1. Use a wrench to turn pump element counter-clock-
wise to loosen. Do not remove entire pump element.
Only back pump element out enough to allow
spacer to be slid on or off.
2. If needed, remove or insert spacers to achieve
required pump output volume. A tool may be
needed to facilitate removal.
Pump volume control is set using either no (0) spac-
ers, 1 or 2 spacers (FIG. 13).
Do not use more than 2 spacers to adjust output vol-
ume.
NOTE:
• The amount of dispensed volume can vary depend-
ing on external conditions such as lubricant tem-
perature and back pressure from downstream
connections.
• Use of these volume adjustment in conjunction with
setting the ON time of the pump will allow for control
of the output volume.
• Use these volume adjustments as a starting point
and adjust as necessary to ensure desired lubrica-
tion dispense.
3. Tighten pump element fitting. Torque fitting to 50 in.
lbs (5.6 N•m).
Loading Grease
To ensure optimal performance from the G3:
• Only use NLGI #000 - #2 greases appropriate for
your application, automatic dispensing, and the
equipment’s operating temperature. Consult with
machine and lube manufacturer for details.
• The reservoir can be filled using a hand operated
pump, pneumatic pump or electric transfer pump.
• Do not overfill (FIG. 16).
• Do not operate G3 without reservoir attached.
No. Spacers
Output Volume / Minute
cubic inches cubic cm
20.122
10.183
00.254
FIG. 13
NOTICE
• Always clean inlet fitting (D) (FIG. 14) with a
clean dry cloth prior to filling reservoir. Dirt
and/or debris can damage pump and/or lubrica-
tion system.
• Care must be used when filling the reservoir
using a pneumatic or electric transfer pump to
not pressurize and break the reservoir.
FIG. 14
D

Setup
18 3A4676B
1. Connect fill hose to inlet fitting (D) (FIG. 15).
2. For higher viscosity fluids, start pump to rotate stir-
ring paddle during fill to prevent air pockets from
forming in grease.
To start the pump press the manual run
button.
3. Fill reservoir with NLGI grease to max
fill line.
NOTE: Vent port, located in rear of reservoir, should not
be used as an overfill port/indicator.
4. Remove fill hose.
Changing Greases
When changing greases, always use compatible fluids
or greases.
Priming
NOTE: It is not necessary to prime pump every time
pump is filled with lubricant.
Pump only requires priming the first time it is used or if it
is allowed to run dry.
1. Loosen pump element fitting (FIG. 17).
NOTE: When loosening pump element fitting, do NOT
loosen pump element. Loosening pump element will
change the output volume
2. Only run pump until air is no longer dispensed with
the lubricant coming out of element fitting (FIG. 18).
3. Tighten pump element fitting using two wrenches
working in opposite directions (FIG. 17).
FIG. 15
FIG. 16
D
E
max fill
line
FIG. 17
FIG. 18

Quick Setup Guide
3A4676B 19
Quick Setup Guide

Quick Setup Guide
20 3A4676B
Control Panel Overview (FIG. 19)
NOTE: Programming instructions begin on page 21.
FIG. 19
DISPLAY
•A blinking LED under HH, MM, SS
or ## identifies type of measurement
unit you are setting; i.e., HH is
hours.
•A blinking number on the display
indicates the G3 is in SETUP
MODE.
•In RUN MODE displayed numbers
count up or down. See Time ON and
Time OFF.
ON / BACKUP TIME
•LED lights when ON
Time/Backup Time is running.
•Display shows time as MM:SS
(minutes and seconds).
i.e., 08:30 is 8 minutes: 30 sec-
onds.
•Sets the limits for the amount
of time to complete a cycle
before an alarm warning is
activated.
•Counts down from a set time to
zero.
OFF TIME
•LED lights when OFF Time is
used to control Pump OFF func-
tion.
•Value is entered in HH:MM (hours
and minutes) or HHHH (hour,
hour, hour, hour) when A8 is on.
•Displays in HH:MM (hours and
minutes) when > 1 hour.
•Times pump rest between lube
events.
•Counts down from set time to
zero.
ALARM ICONS
LED next to icon lights when a
fault / warning event occurs
during a run cycle. See page 32
for a complete description of
these alarm scenarios.
PIN ICON
•LED next to icon lights indi-
cating PIN is required to
enter setup.
•In SETUP MODE LED
lights when setting up the
PIN.
LEFT DIRECTION ARROW /
RESET
•In SETUP MODE: moves cursor
in display one field to the left.
•In RUN MODE: single press
clears warning.
•In RUN MODE: pressing for one
second ends run cycle if no
warnings.
•In ALARM MODE: pressing and
holding for 3 seconds clears
fault / warning and switches
cycle to OFF MODE.
RIGHT DIRECTION ARROW /
MANUAL RUN / ENTER
•In SETUP MODE: saves
entry, moves cursor in display
one field to the right or to the
next setup step.
•In RUN MODE: starts a man-
ual run cycle.
UP and DOWN ARROW
•Hold both the UP and DOWN ARROW but-
tons down together for 3 seconds to enter
SETUP MODE.
•In SETUP MODE: increases or decreases
number values shown in display.