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Instructions
®
G3
Pro Automatic
Lubrication Pump
For dispensing 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 classified 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.
Conforms to ANSI/UL 73
Certified to CAN/CSA
C22.2 No 68
3132066
100-240VAC Pumps ONLY
332298M
EN
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Summary of Contents for Graco G3 Pro
- Page 1 Instructions ® Pro Automatic Lubrication Pump 332298M For dispensing 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 classified 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...
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Page 2: Table Of Contents
Installation ....... . 8 Graco Standard Warranty ....52 Typical Installation . -
Page 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 specific G3 Pump. To help you understand each component that makes up the Model Number see Understanding Your Model Number, page 4. -
Page 4: 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. -
Page 5: Warnings
Warnings 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. - Page 6 Warnings 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. •...
- Page 7 Warnings WARNING 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.
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Page 8: Installation
Pressure Relief Valve (Not included / required for each Vent Hole for Follower Plate (grease models only / not outlet - Available from Graco. See Parts, page 47.) available on all grease models) Zerk Inlet Fill Fitting (1 included / grease models only) -
Page 9: Typical Installation
Installation Typical Installation Series Progressive Divider Valve Installations Connected to fused power source Pressure relief valve (Not included/required for each outlet - user supplied. See Parts, page 48) Series progressive divider valves (Divider Installations) To lube points 332298M... -
Page 10: Typical Installation - With Remote Fill Manifold
Installation 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: G3 Pump Auto-Fill Shut Off Valve... -
Page 11: Optional Installation - Without Remote Fill Manifold
Installation 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. -
Page 12: Choosing An Installation Location
Installation Choosing an Installation Location • 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 AUTOMATIC SYSTEM ACTIVATION HAZARD bracket information. If the system is equipped with has an automatic timer (user supplied) that activates the pump •... -
Page 13: System Configuration And Wiring
Grounding provides an escape wire for the electric current. Fuse Kits are available from Graco. The following Table Improper installation of the grounding conductor identifies the correct fuse to use for the input voltage may result in a risk of electric shock. - Page 14 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. Standard Remote Illumination...
- Page 15 Installation Power DIN AC - 15 foot Power DIN DC - 15 Foot Pin and Related Wire Color (F . 7) Pin and Related Wire Color (F . 6) Pin Name Color -VDC Black Pin Name Color +VDC White Line Black Not Used Not Used...
- Page 16 An Illuminated Remote Run Button Kit: 571030, 571031 Not Used Not Used for starting a manual run cycle if used in conjunction -VDC Black with a 5-wire CPC cable, is available from Graco. +VDC White Contact your local Graco distributor or Graco Customer Not Used Not Used Service for additional information about these kits.
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Page 17: Setup
See Technical Data, page 45. • Install a pressure relief valve close to every pump outlet; before any auxiliary fitting. NOTE: A pressure relief valve can be purchased from Graco. See Parts, page 47. . 10 332298M... -
Page 18: Setting Pump Outlet Volume
• Before making any adjustments to pump volume, follow Pressure Relief on page 17. • Only use Graco supplied spacers to control output volume. 1. Use a wrench to turn pump element . 11 counter-clockwise to loosen. Do not remove entire pump element. - Page 19 Setup max fill line . 14 . 12 4. Remove fill hose. Models Without a Follower Plate Models with Top Fill 1. Connect fill hose to Zerk inlet fitting (D) (F . 13). MOVING PARTS HAZARD Moving parts can pinch, cut or amputate fingers and other body parts.
- Page 20 Setup Models With a Follower Plate 2. Clean the top of the lid and the area around the top of the reservoir to ensure that no debris falls into 1. Connect fill hose to Zerk inlet fitting (D) (F . 13). the reservoir when the lid is removed.
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Page 21: Auto-Fill Shut Off
The fill valve is used to relieve pressure in the refill line or greases. and to reset the Auto Fill Shut Off. See Fill Valve instruction manual 333393. Graco fill valve, Part No. The Auto-Fill Shut Off is used for refilling the G3 77X542 is available. Contact your local Graco reservoir in an automatic lubrication system. - Page 22 NOTE: If the pump does not stall (dead-head) there is a leak in the system. A Pressure Relief Kit: 247902 is available from Graco. Contact your distributor or Graco Customer Service for additional information about this kit. 2. Connect Supply Hose (J) at Quick Connect (V).
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Page 23: Fill Reservoir - Oil Dispense Pumps
Setup Fill Reservoir - Oil Dispense Remote Filling Station Pressure Relief Pumps The reference letters used in the following instructions refer to the Typical Installation diagrams starting on page 9. • Only use oil appropriate for the application, automatic dispensing, and the equipment’s The following Pressure Relief Procedure is only operating temperature. -
Page 24: Prime The Pump
Setup Prime the Pump NOTE: It is not necessary to prime the pump every time the 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 (F . -
Page 25: Quick Setup Guide
Quick Setup Guide Quick Setup Guide 332298M... -
Page 26: Pro Model Setup
Pro Model Setup Pro Model Setup Control Panel Overview (F . 24) NOTE: Programming instructions begin on page 27. DISPLAY OFF TIME • A blinking LED under HH, MM, SS or ## • LED lights when OFF Time sequence is indicates type of measurement unit you running. -
Page 27: Instructions
The G3 controller does not require a user to provide a PIN code to access the programming features of the unit. However, Graco understands that some users may want to protect the program settings and therefore, an option for adding PIN Code authorization is available. - Page 28 OFF Time is set in Hours and Minutes than 30 minutes is entered, the RED (HH: MM). alarm LED lights and the value must be updated. If this time does not meet the application needs, contact Graco Customer Support. 332298M...
- Page 29 1. After you set the OFF Time information and press If this time does not meet the application needs, the ENTER button, the G3 automatically switches contact Graco Customer Support. to the Prelube setup. Programming OFF Time Notice the LED next to the prelube...
- Page 30 Pro Model Setup Delaying the prelube function may be desired if other critical functions or systems of the machine or vehicle are also coming on line during power up. 1. Prelube Delay is set in MM:SS (minutes and seconds). To set the time use the UP or DOWN ARROW button to scroll through numerals 0 to 5 until the...
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Page 31: Advanced Programming
Advanced Programming Advanced Programming There are several Advanced Programming options. The following Table identifies each option and when it is used. Advanced Setting Format/ Description Why Use This? Option Lockout Secures setup modes with Prevents unauthorized users to adjusting settings. Code (Optional) Low Level Alarm MM:SS (minutes:seconds) - Page 32 Advanced Programming Entering a PIN Code for the First Time 1. The cursor is automatically positioned to enter the first character of the PIN Code. A1-Setting Up PIN Code Use the UP and DOWN A PIN Code can be programmed into the G3 to protect ARROW buttons to move up the settings from inadvertently being changed by and down through the numbers 0-9 until the first...
- Page 33 Advanced Programming Fault, and Low Level LED illuminate. flashes and the LED lights under SS; indicating it is ready to program the seconds fields. 5. Repeat steps 1 - 4 to set the SS (seconds) fields. 6. After pressing the ENTER button to set the last SS field, all the programmed ON Time information is saved.
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Page 34: Models With Firmware 5.01 And Later
Advanced Programming Models with Firmware 5.01 and 3. Press the ENTER button to exit Advanced Programming. later A7- Constant Alarm Output ON Fault A8 - 4 Digit Hour OFF Time This function changes the behavior of the alarm output in a fault from either toggling once every second Changes the OFF time from HH:MM to HHHH. -
Page 35: Models With Firmware 5.04 And Later
Advanced Programming Models with Firmware 5.04 and Press the ENTER button. later. A11- Warning Off Through Alarm Relay A10 - Low Level Reset Upon Power On. This function changes the behavior of the alarm output in a This function changes the behavior of the low level upon warning condition to always off. -
Page 36: Models With Firmware 5.06 And Later
Advanced Programming Models with Firmware 5.06 and Press the ENTER button to exit Advanced Programming after the last digit of the later. prelube sequence is displayed. A13- MM:SS OFF Time A12 - Prelube Sequences This function changes the programming of the OFF Time. This function changes the behavior of the prelube function to add more lubrication sequences upon pump start up. -
Page 37: Run Mode
Run Mode Run Mode • When the OFF Time count reaches zero, the G3 Automatic Lubrication Pump turns the pump on and it runs for the programmed ON Time cycle (F Time Control 35). After setup is complete, the G3 automatically begins to (Notice the ON Time LED is now illuminated on the run the OFF Time sequence (F . - Page 38 Run Mode Additional Controls Prelube/Prelube Delay In all models a power OFF/ON cycle can be controlled with the Prelube and Prelube Delay functions. Prelube The Prelube function has been selected. Prelube delay is set to 00:00: MM : SS HH : MM Power to the unit cycles OFF then ON.
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Page 39: Alarms: Firmware Versions 5.01 And Above
Alarms: Firmware Versions 5.01 and Above Alarms: Firmware Versions 5.01 and Above Any time a Fault / Warning occurs, a combination of LED’s will illuminate to notify you there is a problem and help identify the kind of Fault / Warning has occurred. An error message will display and flash every 2 seconds for an alarm, temperature, or current warning, and every 10 seconds for all other types of warnings. - Page 40 Examine the pump to MM : SS HH : MM permanent damage. ensure that it is rotating properly. Warning will self-clear any time after 15 seconds On If necessary, contact Time start if system Graco Customer Service. correction is made. 332298M...
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Page 41: Fault/Warning Scenarios For Firmware Versions 5.06 And Later
Alarms: Firmware Versions 5.01 and Above Fault/Warning Scenarios for Firmware Versions 5.06 and Later Alarm type What it Looks Like What it Indicates Solution Low Power If there is a voltage drop Check voltage and available Warning at the power source current output at the power during operation, the source of the pump. -
Page 42: Troubleshooting
Reservoir is being pressurized during Ensure vent hole is not plugged. the bottom of the reservoir filling If problem persists, contact Graco Customer Service or your local Graco distributor for assistance. Unit not pumping during ON cycle, Failed motor Replace unit. -
Page 43: Maintenance
Maintenance Maintenance Frequency Component Required Maintenance Keep all fittings clean using a clean Daily and at refill Zerk Fittings dry cloth. Dirt and/or debris can damage pump and/or lubrication system. Daily G3 Pump Unit and Reservoir Keep pump unit and reservoir clean using a clean dry cloth. -
Page 44: Parts - 2 Liter Models
Parts - 2 Liter Models Parts - 2 Liter Models 332298M... -
Page 45: Parts - 4 Liter And Larger Models
Parts - 4 Liter and Larger Models Parts - 4 Liter and Larger Models 332298M... -
Page 46: Parts
Parts Parts Part Description Part Description RESERVOIR, 4 L, grease, included 577005 BASE, three pump housing in Kit 571183 RESERVOIR, 4 L, oil, included in kit 25V211 COVER, bottom, with seal 16G020 571182 133767 SCREW, mach, torx pan hd, o-ring 17F484 RESERVOIR, 4 L, G3 AFSO RECT-RING, included in Kit 571042,... - Page 47 Parts † Also order Ref. 57, Part No. 117156 when ordering this part. Part Description Installation and Repair Kits PACKING, o-ring Manual SEAL, upper, reservoir Kit No. Description Number SEAL, lower, reservoir 571026 KIT, output union, 3 pump 3A0523 571063 KIT, output union, 2 pump SPACER, seal, base KIT, return to reservoir NPT, includes...
- Page 48 Parts Pressure Relief Valves Fuses Important Information regarding Pressure Relief Part Description Valve 16C807. 571039 FUSE, 7.5 A for 12 volt DC Pressure Relief Valve 16C807 can only be used on the G3, G1, or G-Mini Pumps. It is not intended for use 571040 FUSE, 4A for 24 volt DC with any other products.
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Page 49: Mount Pattern
Parts Mount Pattern (For correct mounting configuration, choose either Option 1 or Option 2). See P/N 126916 template. Option 1 0.367inch 7.087 inch 9.3 mm 180.0 mm 2x Ø 0.366 inch 1.180 inch 9.3 mm 30.0 mm 3.268 inch 83.0 mm 3.544 inch 90.0 mm Option 2... -
Page 50: Technical Specifications
Technical Specifications Technical Specifications G3 Pro Automatic Lubrication Pump Metric Pump output pressure 5100 psi 35.1 MPa, 351.6 bar Auto-Fill Shut Off maximum inlet 5000 psi 34.4 MPa, 344.7 bar pressure Power 100 - 240 VAC 88-264 VAC; 0.8 A current, 90 VA Power, 47/63 Hz, Single phase, inrush/locked rotor, max 40 A (1ms) 12 VDC 9-16 VDC;... -
Page 51: California Proposition 65
Technical Specifications California Proposition 65 CALIFORNIA RESIDENTS WARNING: Cancer and reproductive harm – www.P65warnings.ca.gov. 332298M... -
Page 52: Graco Standard Warranty
With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.