Graco G3 Pro Bedienungsanleitung

332298E

Instructions

G3 Pro Automatic

Lubrication Pump

For dispensing of 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 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.

ConformstoANSI/UL73

Certified to CAN/CSA

Std. 22.2 No 68-09

3132066

Table of Contents

2332298E

Table of Contents

Part / Model Numbers . . . . . . . . . . . . . . . . . . . . . . . 3

2 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

8 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

12 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 3

16 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Understanding the Model Number . . . . . . . . . . . 4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 8

Typical Installation - With Remote Fill Manifold . . 9

Optional Installation -

Without Remote Fill Manifold . . . . . . . . . . . 10

Choosing an Installation Location . . . . . . . . . . . 11

System Configuration and Wiring . . . . . . . . . . . 12

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Connecting to Auxiliary Fittings . . . . . . . . . . . . . 17

Setting Pump Outlet Volume . . . . . . . . . . . . . . . 18

Loading Grease . . . . . . . . . . . . . . . . . . . . . . . . 18

Auto-Fill Shut Off . . . . . . . . . . . . . . . . . . . . . . . . 20

Filling Oil Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Quick Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . 24

Pro Model Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Control Panel Overview . . . . . . . . . . . . . . . . . . 25

Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Advanced Programming . . . . . . . . . . . . . . . . . . . . 29

Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Fault / Warning Scenarios . . . . . . . . . . . . . . . . . 33

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Parts - 2 Liter Models . . . . . . . . . . . . . . . . . . . . . . 36

Parts - 4 Liter and Larger Models . . . . . . . . . . . . . 37

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Mounting Pattern . . . . . . . . . . . . . . . . . . . . . . . . 42

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 44

Graco Information . . . . . . . . . . . . . . . . . . . . . . . 44

Part / Model Numbers

332298E 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

96G011 G3-G-24PR-2L0L00-R0C00000

96G012 G3-G-24PR-2LFL00-R0C00000

96G013 G3-G-ACPR-2L0L00-0D000000

96G014 G3-G-ACPR-2LFL00-0D000000

96G027 G3-G-12PR-2L0000-00C00000

96G028 G3-G-24PR-2L0000-00C00000

96G029 G3-G-ACPR-2L0000-0D000000

96G033 G3-G-12PR-2L0L05-00C00000

96G034 G3-G-24PR-2L0L05-00C00000

96G070 G3-A-24PR-2L0L00-R0C00000

96G079 G3-A-ACPR-2L0L00-0D000000

Part

Numbers Model Numbers

96G068 G3-G-24PR-4L0L00-R0C00000

96G071 G3-A-24PR-4L0L00-R0C00000

96G073 G3-G-24PR-4LFL00-R0C00000

96G075 G3-G-ACPR-4L0L00-0D000000

96G080 G3-A-ACPR-4L0L00-0D000000

96G082 G3-G-ACPR-4LFL00-0D000000

96G135 G3-G-12PR-4L0000-00C00000

96G137 G3-G-24PR-4L0000-00C00000

96G139 G3-G-ACPR-4L0000-0D000000

96G147 G3-G-12PR-4L0L05-00C00000

96G149 G3-G-24PR-4L0L05-00C00000

96G211 G3-G-24PR-4LAL05-00C00000

Part

Numbers Model Numbers

96G069 G3-G-24PR-8L0L00-R0C00000

96G072 G3-A-24PR-8L0L00-R0C00000

96G076 G3-G-ACPR-8L0L00-0D000000

96G081 G3-A-ACPR-8L0L00-0D000000

96G136 G3-G-12PR-8L0000-00C00000

96G138 G3-G-24PR-8L0000-00C00000

96G140 G3-G-ACPR-8L0000-0D000000

96G148 G3-G-12PR-8L0L05-00C00000

96G150 G3-G-24PR-8L0L05-00C00000

96G208 G3-G-ACPR-8LAL00-0D00000

96G214 G3-G-24PR-8LAL05-00C00000

Part

Numbers Model Numbers

96G077 G3-G-ACPR-120L00-0D000000

96G163 G3-G-24PR-120L05-00C00000

Part

Numbers Model Numbers

96G078 G3-G-ACPR-160L00-0D000000

96G167 G3-G-24PR-160L05-00C00000

Part / Model Numbers

4332298E

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

• 12 = 12 Volts DC

• 24 = 24 Volts DC

• AC = 100 - 240 Volts AC

Code bb: Operation Control

• PR = Pro (Timer) Control

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

• F = Follower Plate Installed

• 0 = No Follower Plate

• A - Auto-Fill Shut Off

Code e: Low Level Option

• L = Low Level with Controller

• 0 = No Low Level monitoring

Code ff: Options

• 00 = No Options

• 05 = 5 Pin CPC power cable

• 07 = No Power Cord

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

• R = Remote Manual Run

• 0 = Not populated

G3 -G- PR 0 00 0

Code Sample: a a b b - c c d e f f - g h i j k m n p

FIG. 1

Warnings

332298E 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 offanddisconnectpoweratmainswitchbeforedisconnectinganycablesandbeforeservicing

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 voidagency 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

6332298E

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.

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

332298E 7

Installation

Component Identification

Key:

A Reservoir

B Pump Element (1 included. Can accommodate 3 total)

C Pressure Relief Valve (Not included / required for each

outlet - Available from Graco. See Parts, page 40.)

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. 15, page 18)

G Fuse (DC models only - Not included, not shown.

Available from Graco. See Parts, page 39.)

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 (DIN shown)

L Follower Plate (grease models only / not available on all

grease models)

M Vent Hole for Follower Plate (grease models only / not

available on all grease models)

N Fill cap (oil models only)

R Auto-Fill Shut Off

FIG. 2:

G3-G-24PR-2LFL00-R0C00000

Grease Models with Follower

Plate

96GXXX

Oil Models

Grease Models

Auto-Fill Shut Off Models

Installation

8332298E

Typical Installation

Series Progressive Divider Valve Installations

A Connected to fused power source

B Pressure relief valve (Not included/required for each outlet

- user supplied. See Parts, page 40)

C Series progressive divider valves (Divider Installations)

D To lube points

FIG. 3

Installation

332298E 9

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:

AG3Pump

B Auto-Fill Shut Off Valve

C Auto-Fill Inlet

D G3 Reservoir

E Remote Fill Reservoir

F Remote Fill Pump

G Supply Hose (user supplied)

H Air Supply to Refill Pump

J Supply Hose (user supplied)

K Pressure Relief Valve

L Drain Hose

M Fill Coupler/Inlet (quick disconnect)

N Fill Manifold

P Fill Manifold Outlet

Q Fill Manifold Vent Port

R Pressure Gauge

S Pressure Regulator and Gauge

T Pressure Relief Knob

To relieve the stall pressure in the fill line a fill manifold

(N) must be installed in the system.

FIG. 4

Installation

10 332298E

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.

Key:

AG3Pump

B Auto-Fill Shut Off Valve

C Auto-Fill Inlet

D G3 Reservoir

E Remote Fill Reservoir

F Remote Fill Pump

HReliefValve

J Supply Hose (user supplied)

LDrainTube

L1 Option - To reservoir

L2 Option - To overflow container

S Pressure Regulator and Gauge

U Pressure Relief Valve

V Quick Disconnect

W Overflow Container

Y Supply Hose Pressure Relief Valve

To relieve the stall pressure in the fill line a ball valve

(Y) must be installed in the system.

FIG. 5

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