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.