Graco 332298B G3 Pro Automatic Lubrication Pump Users Manual 332298B, Pump, English

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332298B

EN

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) Maximum Working Pressure

Important Safety Instructions

Read all warnings and instructions in this

manual. Save these instructions.

Conforms to ANSI/UL 73

Certified to CAN/CSA

Std. 22.2 No 68-09

3132066

Table of Contents

2332298B

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

Choosing an Installation Location . . . . . . . . . . . . 9

System Configuration and Wiring . . . . . . . . . . . 10

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Connecting to Auxiliary Fittings . . . . . . . . . . . . . 18

Setting Pump Outlet Volume . . . . . . . . . . . . . . . 19

Loading Grease . . . . . . . . . . . . . . . . . . . . . . . . 19

Filling Oil Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Quick Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . 21

Pro Model Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Control Panel Overview . . . . . . . . . . . . . . . . . . 22

Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Advanced Programming . . . . . . . . . . . . . . . . . . . . 26

Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Fault / Warning Scenarios . . . . . . . . . . . . . . . . . 30

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Parts - 2 Liter Models . . . . . . . . . . . . . . . . . . . . . . 33

Parts - 4 Liter and Larger Models . . . . . . . . . . . . . 34

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Mounting Pattern . . . . . . . . . . . . . . . . . . . . . . . . 41

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 42

Graco Information . . . . . . . . . . . . . . . . . . . . . . . 42

Part / Model Numbers

332298B 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

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

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

4332298B

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

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

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

k

m

np

h

j

i

g

Warnings

332298B 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

regulations.

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 manu-

facturer’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.

+

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.

Warnings

6332298B

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 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. 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 manufacturer

WARNING

Installation

332298B 7

Installation

Grounding

Component Identification

Key:

A Reservoir

B Adjustable Pump Element (1 included. Can accommodate

3 total)

C Pressure Relief Valve (Not included / required for each

outlet - Available from Graco. See Parts, page 38.)

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. 12, page 19)

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

Available from Graco. See Parts, page 38.)

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)

The equipment must be grounded. Grounding reduces the risk of electric shock by providing an escape wire

for the electrical current in the event of malfunction or breakdown. This product is equipped with a cord having

an equipment grounding conductor. The wire with insulation having an outer surface that is green with or

without yellow stripes is the grounding wire.

FIG. 2:

A

D

H

I

B

E

C

K

F

J

G3-G-24PR-2LFL00-R0C00000

Grease Models with Follower

Plate

L

M

96GXXX

Oil Models

N

Grease Models

Installation

8332298B

Typical Installation

Divider Installations

A Connected to fuse / power

B Pressure relief valve (Not included/required for each

outlet - user supplied. See Parts, page 38)

C - Cycle indicator sensor cable to external controller

(Divider Installations)

- Pressure switch cable to external controller (Injector

Installations)

D - Series progressive divider valves (Divider Installations)

- Injectors (Injector Installations)

E To lube points

F - Proximity Switch (Divider Installations)

- Pressure switch (Injector Installations)

A

B

C

D

E

F

Installation

332298B 9

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 two mounting hole layouts provided

in the Mounting Pattern section of this manual,

page 41.

NOTE: The two mounting hole layouts provided

in the Technical Data section show the only cor-

rect installation patterns to use for mounting the

G3. No other installation configurations should

be used.

• Use designated mounting holes and provided

configurations only.

• Always mount the G3 oil models upright.

• If the G3 grease model is going to be operated

in a tilted or inverted position for any period of

time, you must use a model that includes a fol-

lower plate, otherwise the G3 must be mounted

upright. Refer to your model number to confirm

if a follower plate was installed on your pump.

See page 4, Understanding the Model Number

to identify this character in your model number.

• Use the three fasteners (included) to secure the

G3 to the mounting surface.

• Some installations may require an additional

reservoir support bracket. Consult your Graco

distributor for assistance with this installation.

AUTOMATIC SYSTEM ACTIVATION HAZARD

Unexpected activation of the system could result in serious injury, including skin injection and amputation.

This device has an automatic timer that activates the pump lubrication system when power is connected or when

exiting the programming function. Before you install or remove the lubrication pump from the system, disconnect and

isolate all power supplies and relieve all pressure.

Installation

10 332298B

System Configuration and Wiring

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.

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.

• 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.

.

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.

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

332298B 11

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.

Wiring and Installation Diagrams

The following Table identifies the wiring and installation diagrams provided in this manual.

Standard Remote Illumination

(via 5 wire CPC power cable)

Tri-Color Remote Illumination

(via illuminated manual run input)

Unit in OFF Mode Off Off

Unit in ON Mode On Green

Warning Condition Toggles On and Off once per second Yellow

Fault Condition Toggles On and Off once per second Red

Diagram Symbol Page #

Power DIN AC 12

Power DIN DC 13

Power CPC DC 15

Illuminated Manual Run Input Kits: 571030, 571031,

571032, 571033

Installation

12 332298B

Power DIN AC - 15 foot: Part No. 16U790

Pin and Related Wire Color (FIG. 3)

Pin Pin Name Color

1 Line Black

2 NEUTRAL White

3 Not Used Not Used

4GROUND Green

FIG. 3

(4)

(2)

(1)

1

2

3

4

Example Wiring Diagram

Connector on Housing Connector on Cable

(4)

(1)

(3)

(2)

Installation

332298B 13

Power DIN DC - 15 Foot: Part No. 16U790

Pin and Related Wire Color (FIG. 4)

NOTICE

Be sure when power is applied that stirring paddle

rotates clockwise (when viewed from the top). If it is

wired incorrectly paddle could rotate counter-clockwise

which will damage the pump’s internal components. If

this happens, stop the pump immediately and wire unit

correctly.

Pin Pin Name Color

1-VDC Black

2+VDC White

3 Not used Not used

4 Not used Green

FIG. 4

Ignition Switch

Fuse

1

2

3

4

Example Wiring Diagram

Connector on Housing

12V-pump - 7.5A - Graco kit #571039

24V pump - 4A - Graco kit #571040

(4)

(2)

(1)

Connector on Cable

(4)

(1)

(3)

(2)

Installation

14 332298B

Power CPC DC - 15 foot: Part No. 126217

Pin and Related Wire Color (FIG. 5)

Pin Pin Name Color

1 Not Used Not Used

2-VDC Black

3+VDC White

4 Not Used Not Used

5 Not Used Not Used

6 Not Used Not Used

7 Not Used Green

FIG. 5

(1)

(2)

(3)

(4)

(5)

(6)

(7)

Example Wiring Diagram

Connector on Housing Connector on Cable

Ignition Switch

Fuse

1

2

3

4

5

6

7

12V-pump - 7.5A - Graco kit #571039

24V pump - 4A - Graco kit #571040

(1)

(3)

(2)

(7)

(6) (5)

(4)

Installation

332298B 15

Power CPC DC - 5 Wire

Part No.: 126218: 15 ft (4.5 m)

Part No.: 126219: 20 ft (6.1 m)

Part No.: 126220: 30 ft (9.1 m)

NOTE: An Illuminated Remote Run Button Kit: 571030 -

12V or 571031- 24V, for starting a manual run cycle if

used in conjunction with a 5-wire CPC cable, is available

from Graco. Contact your local Graco distributor or

Graco Customer Service for additional information

about these kits.

Pin and Related Wire Color(FIG. 6)

Pin Pin Name Color

1 Not Used Not Used

2-VDC Black

3+VDC Red

4LIGHT White

5 MANUAL ORANGE

6 Not Used Not Used

7 Not Used Green

FIG. 6

(1)

(2)

(3)

(4)

(5)

(6)

(7)

1

2

3

4

5

6

7

L

Fuse 12V-pump - 7.5A - Graco kit #571039

24V pump - 4A - Graco kit #571040

Example Wiring Diagram

Connector on Housing Connector on Cable

(1)

(3)

(2)

(7)

(6) (5)

(4)

Installation

16 332298B

Part No. 124333: Cable Pin Out (M12)

Wire Colors

Part No. 124300: Field Wireable Pin Out

(M12)

Wire Colors

Item No. Color

1Brown

2White

3Blue

4Black

FIG. 7























Item No. Color

1Brown

2White

3Blue

4Black

FIG. 8













Installation

332298B 17

Part No. 124594: 4 Pin Eurofast Field

Wireable Connector

Part No. 124595: 5 Pin Eurofast Field

Wireable Connector

FIG. 9









FIG. 10











Setup

18 332298B

Setup

Pressure Relief

Follow the Pressure Relief Procedure whenever

you see this symbol.

Relieve pressure in system using two wrenches work-

ing 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 fit-

ting.

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 38.

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 spraying and before

cleaning, checking, or servicing the equipment.

FIG. 11

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

element or auxiliary fittings. See FIG. 11 for an

example.

• 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 alleviate unin-

tended pressure rises in the system and protect the G3

pump from damage.

• Only use a pressure relief valve that is rated for no

more than the working pressure of the G3 pump it

is installed on. See Technical Data, page 34.

• Install a pressure relief valve close to every pump

outlet; before any auxiliary fitting.

Setup

332298B 19

Setting Pump Outlet Volume

NOTE:

• Before making any adjustments to pump volume,

Relieve Pressure following procedure on page 18.

• Only use Graco supplied spacers to control output

volume.

• It may be necessary to repeat this outlet volume

setup procedure after the pump is operating to

re-adjust the volume of dispensed fluids.

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.

NOTE: 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) spacers,

1 or 2 spacers (FIG. 12).

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.

2. 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. 14).

• Do not operate G3 without reservoir attached.

No. Spacers

Output Volume / Minute

cubic inches cubic cm

20.122

10.183

00.254

FIG. 12

NOTICE

• Always clean fitting (D) with a clean dry cloth

prior to filling reservoir. Dirt and/or debris can

damage pump and/or lubrication system.

• Care must be used when filling the reservoir

using a pneumatic or electric transfer pump to

not pressurize and break the reservoir.

Setup

20 332298B

Models without a follower plate:

1. Connect fill hose to inlet fitting (FIG. 13).

2. For higher viscosity fluids, start pump to rotate stir-

ring paddle during fill to prevent air pockets from

forming in grease.

Start pump by pressing 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.

Models with a follower plate:

1. Connect fill hose to inlet fitting (FIG. 13).

2. For higher viscosity fluids, start pump to rotate stir-

ring paddle during fill to prevent air pockets from

forming in grease.

Start pump by pressing the manual run

button.

3. Fill reservoir with grease until seal of

follower plate breaches the vent hole (FIG. 15) and

the majority of air is expelled from the reservoir.

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.

Filling Oil Unit

• Only use oil appropriate for your application, auto-

matic dispensing, and the equipment’s operating

temperature. Consult with machine and lube manu-

facturer 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.

• Only use oils with viscosity at least 40 cSt.

FIG. 13

FIG. 14

D

E

max fill line

FIG. 15

vent hole

Quick Setup Guide

332298B 21

1. Remove fill cap (a).

2. Pour oil into reservoir to fill line (b).

3. Replace fill cap. Hand tighten cap, securely.

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).

Quick Setup Guide

FIG. 16

a

b

FIG. 17

FIG. 18



 







































Pro Model Setup

22 332298B

Pro Model Setup

Control Panel Overview (FIG. 19)

NOTE: Programming instructions begin on page 23.

FIG. 19

ON OFF

!

HH MM SS ##

MM : SS HH : MM

DISPLAY

•A blinking LED under HH, MM, SS or ##

indicates type of measurement unit you

are setting; i.e., HH is hours.

•A blinking number on the display indi-

cates the G3 is in SETUP MODE.

•In RUN MODE displayed numbers count

up or down. See Time ON and Time

OFF.

ON TIME

•LED lights when ON Time

sequence is running.

•Display shows time as MM:SS

(minutes and seconds).

i.e., 08:30 is 8 minutes: 30 sec-

onds.

•Times lubrication cycle.

OFF TIME

•LED lights when OFF Time sequence is

running.

•Value is entered in HH:MM.

•Displays in HH:MM (hours and minutes)

when > 1 hour.

•Displays in MM:SS (minutes and second)

ALARM ICONS

LED next to icon lights when a

fault / warning event occurs

during a run cycle. See page 30

for a complete description of

these alarm scenarios.

LOCK ICON

•LED next to icon lights indi-

cating PIN is required to

enter setup.

•In SETUP MODE LED

lights when setting up the

PRELUBE

LED next to icon lights indicat-

ing Prelube function is enabled.

LEFT DIRECTION ARROW /

RESET

•In SETUP MODE, moves cur-

sor in display one field to the

left.

•In RUN MODE: single press

clears warning.

•In ALARM MODE: pressing and

holding for 3 seconds clears

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.

Pro Model Setup

332298B 23

Instructions

Powering Units With Controllers

By default, units with controllers are set to

operate in a timed mode with 1 minute of

ON time and 8 hours of OFF time. The unit

should be powered up in OFF mode,

counting down from the 8 hours. If the unit powers up in

ON mode and has not been primed, hold the reset but-

ton located on the control panel (example shown on the

right) for 1 second to move to the OFF mode.

The Pro Model uses a timer to regulate how long a

pump cycle runs and the length of time the pump rests

between cycles.

NOTE:

• A blinking number on the display indicates the G3 is

in SETUP MODE.

• In RUN MODE numbers on the display do not blink.

• After 60 seconds of no activity, the device returns to

RUN MODE in the OFF Time cycle and the OFF

Time restarts counting down the total programmed

amount of time. It does not resume the countdown

from the point where the cycle was interrupted when

you entered SETUP MODE.

Entering Setup Mode

Press both the UP and DOWN

ARROW buttons together for 3

seconds to enter the SETUP

MODE.

NOTE: If the lock LED is

lit after entering Setup

Mode and four 0000’s

are displayed, the unit

has a PIN Code lock out

enabled. See Entering a

PIN Code to Access

Setup Mode for instruc-

tions on entering a value.

Entering a PIN Code to Access Setup Mode

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.

The instructions for setting a PIN Code are provided in

the Advanced Programming section of this manual. See

page 26.

To enter the PIN Code:

1. Press both the UP and

DOWN ARROW buttons for 3

seconds.

2. The LED next to the LOCK ICON on

the display lights and the 4 zeros

appear on the display indicating the

system requires a PIN Code entry to access the G3

in SETUP MODE.

3. The cursor is automatically

positioned to enter the first

character of the PIN Code.

Use the UP and DOWN

ARROW buttons to move up

and down through the numbers 0-9 until the first

number in the PIN code is displayed in the field.

4. Press the ENTER button to set the num-

ber. The cursor automatically moves to

the next number field.

5. Repeat steps 3 and 4 for each PIN Code prompt

field.

If the PIN Code you entered is correct, the first editable

character on the display will flash.

NOTE: A blinking field on the display indicates the G3 is

in SETUP MODE. In RUN MODE numbers on the dis-

play will not blink.

ON Time

• The LED next to the clock in the ON

field lights, indicating you are setting

the ON Time parameters.

• ON Time is set in Minutes and Seconds (MM: SS).

Pro Model Setup

24 332298B

• An LED flashes under

either MM when pro-

gramming minutes

OR SS when pro-

gramming seconds.

• In SETUP MODE, the

number displayed in

the first field, on the

left side of display

blinks, indicating the

device is ready to pro-

gram the ON Time minutes.

• The total amount of ON Time cannot

exceed 30 minutes. If a value greater

than 30 minutes is entered, the RED

alarm LED lights and the value must

be updated.

If this time does not meet the application needs,

contact Graco Customer Support.

Programming ON Time

NOTE: When programming a time of less than 10 min-

utes you must program a leading zero in the first num-

ber field and press the ENTER button to save the zero

selection.

1. To set the ON Time use the

UP or DOWN ARROW button

to scroll through numerals 0

to 5 until the desired number

appears in the first MM (min-

utes) field.

2. Press the ENTER button to lock in the

selection. The next MM number field to

the right flashes indicating it is ready for

programming.

3. Use the UP or DOWN

ARROW button to scroll

through numerals 0 to 9 until

the desired number appears

in the second MM number

field.

4. Press the ENTER button to lock in the

selection.

The next number field to the right

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.

The G3 automatically switches to the OFF Time

SETUP MODE.

OFF Time

• The LED next to the clock in the OFF

field lights, indicating you are setting

the OFF Time parameters.

• OFF Time is set in Hours and Minutes

(HH: MM).

• An LED flashes under

either HH when pro-

gramming hours OR

MM when program-

ming minutes.

• In SETUP MODE the

number displayed in

the first field, on the

left side of display

blinks, indicating the

device is ready to pro-

gram the OFF Time hours.

• The total amount of OFF Time must be

at least twice as long as the pro-

grammed ON Time. If a value less

than twice the ON Time is entered, the

RED alarm LED lights and the value must be

updated.

If this time does not meet the application needs,

contact Graco Customer Support.

Programming OFF Time

NOTE: When programming a time of less than 10

hours you must program a leading zero in the first

number field and press the ENTER button to save the

zero selection.

1. To set the OFF Time use the

UP or DOWN ARROW button

to scroll through numerals 0

to 9 until the desired number

appears in the first HH (hour)

field.

OR

OR

Pro Model Setup

332298B 25

2. Press the ENTER button to lock in the

selection. The next HH number field to

the right flashes indicating it is ready for

programming.

3. Use the UP or DOWN

ARROW button to scroll

through numerals 0 to 9 until

the desired number appears

in the second HH number

field.

4. Press the ENTER button to lock in the

selection.

The next number field to the right

flashes and the LED lights under MM; indicating it is

ready to program the minutes fields.

5. Repeat steps 1 - 4 to set the next MM (minutes)

fields.

6. After pressing the ENTER button to set

the last MM field, the OFF Time informa-

tion is saved.

Prelube

The Prelube function determines operation of the pump

when power is applied. It can be set to OFF or ON.

OFF (default) - The unit resumes its lubrication cycle at

the point it was at when power was removed.

ON - The unit begins a pump cycle.

Setting Prelube

1. After you set the OFF Time information and press

the ENTER button, the G3 automatically switches to

the Prelube setup.

Notice the LED next to the prelube

icon on the G3 display lights indicat-

ing you are now in the Prelube setup

mode.

2. OFF displays. If you

want the prelube

cycle to begin imme-

diately, leave this set

to OFF.

3. Press the ENTER button to set the

selection.

4. If you want to set a

prelube delay time,

press the DOWN

ARROW button to

change OFF to ON

on the display.

Prelube Delay

Prelube Delay can be entered to delay the start of the

pump’s cycle on power up. If prelube is set to ON, a pre-

lube delay time in MM:SS must be entered. By default,

the delay is set to 0 (begin an ON cycle immediately).

Delaying the prelube function may be desired if other

critical functions or systems of your machine or vehicle

are also coming on line during power up.

1. Prelube Delay is set in

MM:SS (minutes and sec-

onds). To set the time use the

UP or DOWN ARROW button

to scroll through numerals 0

to 5 until the desired number

appears in the first MM (minutes) field.

The maximum length of time Prelube Delay can be

set to is 59:59 (59 minutes:59 seconds).

2. Press the ENTER button to lock in the

selection. The next MM number field to

the right flashes indicating it is ready for

programming.

3. Use the UP or DOWN

ARROW button to scroll

through numerals 0 to 9 until

the desired number appears

in the second MM number

field.

4. Press the ENTER button to lock in the

selection.

The next number field to the right

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 the G3 automatically

switches to the RUN MODE.

Advanced Programming

26 332298B

Advanced Programming

There are 2 Advanced Programming options. The following Table identifies each option and when it is used.

Entering a PIN Code for the First Time

A1-Setting Up PIN Code

A PIN Code can be programmed into the G3 to protect

the settings from inadvertently being changed by unau-

thorized users.

1. Press the UP ARROW button for 10

seconds.

The LED next to the LOCK ICON on the

display lights, indicating you have entered

the PIN Mode.

2. The word OFF appears in the

display. Press the UP or

DOWN ARROW button to

change this to ON.

3. Press the ENTER button to enter the

PIN Code.

4. The cursor automatically is

positioned to entered the first

character of the PIN Code.

Use the UP and DOWN

ARROW buttons to move up

and down through the numbers 0-9 until the first

number in the PIN code is displayed in the field.

5. Press the ENTER button to set the

number. The cursor automatically

moves to the next number field.

6. Repeat steps 4 and 5 for each PIN Code prompt

field.

7. Press the ENTER button to save the

PIN Code and exit Advanced Setup.

Entering Advanced Setup

Press the UP ARROW button for 10 sec-

onds.

If the G3 was previously set up to require a

PIN Code, the LED next to the LOCK ICON lights, indi-

cating a PIN Code is required.

1. The cursor is automatically

positioned to enter the first

character of the PIN Code.

Use the UP and DOWN

ARROW buttons to move up

and down through the numbers 0-9 until the first

number in the PIN code is displayed in the field.

2. Press the ENTER button to set the num-

ber. The cursor automatically moves to

the next number field.

3. Repeat steps 1 and 2 for each PIN Code prompt

field.

If the PIN Code you entered is correct, the first editable

character on the display will flash.

Advanced

Option Setting Format/ Description Why Use This?

A1 Lockout

Code

(Optional)

Secures setup modes with PIN Prevents unauthorized users to adjusting settings.

A2 Low Level

Alarm Time

MM:SS (minutes:seconds) sets

amount of time between Low

Level Warning to Low Level Fault.

Default = 3 minutes

To accommodate most lubrication situations, a con-

servative amount of time is programmed between

the low level warning and fault to help protect unit

from running dry. If necessary the amount of time

the unit runs before stopping due to a low level fault

can be adjusted.

Advanced Programming

332298B 27

Selecting Advanced Setup Options

1. Press the UP or DOWN

ARROW button to move up

or down through Advanced

Options A1 and A2.

2. Press the ENTER button to set the

selection.

A2 - Low Level Alarm Time

Pump ON mode only.

Programs the amount of time in MM: SS (minutes and

seconds) the pump can run between a Low Level Warn-

ing and a Low Level Fault to help protect unit from run-

ning dry.

The maximum recommended length of time is 3:00 min-

utes.

Fault, and Low Level LED illuminate.

NOTE: When programming a time of less than 10 min-

utes you must program a leading zero in the first num-

ber field and press the ENTER button to save the zero

selection.

1. To set the time use the UP or

DOWN ARROW button to

scroll through numerals 0 to 9

until the desired number

appears in the first MM (min-

utes) field.

2. Press the ENTER button to lock in the

selection. The next MM number field to

the right flashes indicating it is ready for

programming.

3. Use the UP or DOWN

ARROW button to scroll

through numerals 0 to 9 until

the desired number appears

in the second MM number

field.

4. Press the ENTER button to lock in the

selection.

The next number field to the right

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.

Unit exits Advanced Programming.

FIG. 20

ON OFF

!

HH MM SS ##

MM : SS HH : MM

Run Mode

28 332298B

Run Mode

Time Control

After setup is complete, the G3 automatically begins to

run the OFF Time sequence (FIG. 21).

• The G3 runs the programmed OFF sequence.

(Notice the OFF Time LED on the display lights and

the OFF Time counts down on the display.)

• The example shown in FIG. 21 shows an OFF Time

of 1 hour and 32 minutes before the lubrication

cycle begins.

• 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 (FIG. 22).

(Notice the ON Time LED is now illuminated on the

display.)

• The example shown in FIG. 22 shows an ON Time

of 8 minutes and 42 seconds before the lubrication

cycle ends.

• When the ON Time count reaches zero, the pump

shuts off again and the system again runs OFF

Time cycle and the OFF Time LED is now again illu-

minated (FIG. 21).

This sequence repeats itself until the device is

reprogrammed or an alarm occurs.

Manual Run Cycle

To run an extra (non-programmed) lubrica-

tion cycle, push the Manual Start button.

FIG. 21

ON OFF

!

HH MM SS ##

MM : SS HH : MM

FIG. 22

ON OFF

!

HH MM SS ##

MM : SS HH : MM

Run Mode

332298B 29

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:

• Power to the unit cycles OFF then ON.

• Unit immediately begins a lubrication cycle.

• Pro Model - display shows ON Time (See Time

Control, page 28).

Prelube Delay

The Prelube function has been selected. Prelube delay

is set to something other than 00:00:

• Power to the unit cycles OFF then ON.

• Unit immediately begins the Prelube Delay

count down until the lubrication cycle begins.

• The LED next to the clock in the OFF field is illu-

minated (FIG. 23).

• The Prelube LED lights (FIG. 23).

• The display shows time remaining until lubrica-

tion cycle begins. The example shown in FIG. 23

shows 8 minutes and 14 seconds left until a

lubrication cycle begins.

Manual Run Cycle

To run an extra (non-programmed) lubrica-

tion cycle, push the Manual Start button.

NOTE: Manual Run option is not available while unit is

in Vent Mode.

FIG. 23

ON OFF

!

HH MM SS ##

MM : SS HH : MM

Alarms

30 332298B

Alarms

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.

• Faults and Warnings will not automatically clear.

• To clear an fault, press and hold the RESET button on the display button pad for 3 seconds.

• To clear a warning press and immediately release the RESET button.

Fault / Warning Scenarios

The following pages describe the most likely fault / warnings you could receive.

Alarm Type What it Looks Like What it Indicates Solution

Low Level

Warning

Level of lubricant in

reservoir is low and addi-

tional lubricant needs to be

added.

Unit continues to operate

as normal for a limited

period of time until a low

level alarm is triggered.

Add lubricant to reservoir.

After lubricant

is added,

press the

RESET but-

ton to clear the warning.

Low Level

Fault

Level of lubricant in

reservoir is low and addi-

tional lubricant needs to be

added.

Unit stops pumping and

displays amount of accu-

mulated time since the

alarm was triggered.

Add lubricant to reservoir.

After lubri-

cant is

added press

and hold the

RESET button to clear

fault.

If repriming pump is

required, the low level

alarm time should be

decreased. See A-2:

Advanced Programming,

Low Level Alarm Time

page 27.

ON OFF

!

HH MM SS ##

MM : SS HH : MM

ON OFF

!

HH MM SS ##

MM : SS HH : MM

Troubleshooting

332298B 31

Troubleshooting

Problem Cause Solution

Unit does not power on Incorrect/loose wiring Refer to Installation instructions, page

7.

Unit does not power on (DC models

only)

Tripped external fuse due to internal

component failure Contact Graco Customer Service.

Tripped external fuse due to pumping

non-cold weather lubricant in cold

weather -13°F (-25°C)

Replace lubricant with pumpable

lubricant, rated for environmental con-

ditions and application.

Replace fuse.

Unit does not power on (AC models

only)

Tripped internal power supply fuse

due to power supply failure Contact Graco Customer Service.

Can’t set desired ON/OFF times

Maximum duty cycle is 33% (2 min-

utes OFF for each minute ON)

Adhere to allowable duty cycle. Con-

tact Graco Customer Support if other

duty cycles are required for applica-

tion.

Unit is not operating based on the

time that was programmed

Time entered was misinterpreted as

MM:SS instead of HH:MM (or visa

versa)

Verify the unit was programmed as

intended, referencing programming

instructions. Note the dot designation

for hours, minutes, seconds on the

top row of the display.

Lubricant leaks past seal located on

the bottom of the reservoir

Reservoir retaining tabs are cracked

or broken

Replace reservoir.

Reservoir is being pressurized during

filling

Ensure vent hole is not plugged.

If problem persists, contact Graco

Customer Service or your local Graco

distributor for assistance.

Unit not pumping during ON cycle, but

controller lights and functions

Failed motor Replace unit.

Follower plate is not going down

Air is trapped in the reservoir between

the follower plate and lubricant

Add grease following Loading Grease

instructions, page 19. Ensure air is

purged.

Pump takes several minutes before it

begins pumping at the highest pump

volume setting (no stroke adjust spac-

ers installed)

Pumping non-cold weather lubricant

in cold weather -13°F (-25°C)

Add 1 stroke adjust spacer and adjust

lube cycle time to accommodate the

difference in pump volume per stroke.

Dim display, unit is not operating

Tripped internal, resettable fuse due

to internal component failure or sen-

sor short circuit condition

Verify sensor and manual run inputs

have not created a short circuit condi-

tion. Cycle power.

Maintenance

32 332298B

Maintenance

Frequency Component Required Maintenance

Daily and at refill Zerk Fittings Keep all fittings clean using a clean

dry cloth. Dirt and/or debris can dam-

age pump and/or lubrication system.

Daily G3 Pump Unit and Reservoir Keep pump unit and reservoir clean

using a clean dry cloth.

Daily Display Keep display clean using a clean

dry cloth.

Monthly External Wiring Harness Verify external harnesses are

secure.

Parts - 2 Liter Models

332298B 33

Parts - 2 Liter Models

35

16

15

27 1

45

60

23

57

40a

44

14

1

42

13

18

17

34

36

33

37

41

21

30

15

43

31

Follower Plate

Models Only

43

Torque to 4 in. lbs (0.45 N.m)

1

Torque to 30 in. lbs (3.4 N.m)

2

Torque to 50 in. lbs (5.6 N.m)

3

2

3

40b

3

Low Level Grease Models Only

Low Level Oil Models Only

66

67

12

Parts - 4 Liter and Larger Models

34 332298B

Parts - 4 Liter and Larger Models

40a

44

35

14

1

41

13

18

17

34

16

36

33

37

42

21

30

15

43

31

Follower Plate

Models Only

43

Torque to 4 in. lbs (0.45 N.m)

1

Torque to 30 in. lbs (3.4 N.m)

2

Torque to 50 in. lbs (5.6 N.m)

3

2

3

61

62

40b

3

27 1

45

60 23

57

Low Level Grease Models Only

67

66

Low Level Oil Models Only

13

12

Parts

332298B 35

Parts

Ref Part Description Qty

1 BASE, three pump housing 1

3 278142 COVER, bottom, with seal 1

4 115477 SCREW, mach, torx pan hd 9

12 127079 RECT-RING, included in Kit

571042, 571069, 571179 1

13 124396

O-RING, 258, included in Kit

571042, 571044, 571045,

571069, 571179

2

14 PLATE, ricer 1

15 BEARING, ball 1

16

PADDLE, stirring, 2 Liter models

without follower plate - models

96G011, 96G013, 96G027,

96G028, 96G029, 96G033,

96G034, included in Kit 571044,

96G178

1

PADDLE, stirring, 4 Liter models

without follower plate - models

96G068, 96G075, 96G135,

96G137, 96G139, 96G147,

96G149

1

PADDLE, stirring, 8 Liter models

without follower plate - models

96G069, 96G076, 96G136,

96G138, 96G140, 96G148,

96G150

1

PADDLE, stirring, 12 Liter mod-

els without follower plate - mod-

els 96G077, 96G163

1

PADDLE, stirring, 16 Liter mod-

els without follower plate - mod-

els 96G078, 96G167

1

PADDLE, stirring, 2 Liter models

with follower plate - models

96G012, 96G014, included in Kit

571045

1

PADDLE, stirring, 4Liter models

with follower plate - models

96G073, 96G082

1

17 PUMP, element, 96G073,

96G082 included in Kit 571041 1

18 16F368 SPACER, stroke adjust, included

in Kit 571041 2

21 278145 PLUG, pump, 3/4-16 2

23278136

PADDLE, low level, models

96G011-96G014, 96G033,

96G034, 96G068, 96G069,

96G073, 96G075-96G078,

96G082, 96G147, 96G148,

96G149, 96G150, 96G163,

96G167

1

27 123025

SCREW, M6, models

96G011-96G014, 96G033,

96G034, 96G068, 96G069,

96G073, 96G075-96G078,

96G082, 96G147, 96G148,

96G149, 96G150,96G163,

96G167

1

30

‡258760

BOARD, circuit, Pro, models

96G011 - 96G014,

96G027-96G029, 96G033,

96G034, 96G069-96G073,

96G075-96G082,

96G135-96G140, 96G147,

96G148, 96G150, 96G163,

96G167

1

31 119228

SCREW, machine, flat head,

models 96G011-96G014,

96G027-96G029, 96G033,

96G034, 96G069-96G072,

96G075-96G082,

96G135-96G140, 96G147,

96G148, 96G149, 96G150,

96G163, 96G167

2

3316A579 LABEL, safety 1

34 16A578

LABEL, overlay, models

96G011-96G014,

96G027-96G029, 96G033,

96G034, 96G069-96G072,

96G075-96G082,

96G135-96G140,

96G147,-96G150, 96G163,

96G167

1

Ref Part Description Qty

Parts

36 332298B

35

WIPER, stirring, models without

follower plate - models 96G011,

96G013, 96G027-96G029,

96G033, 96G034, 96G068,

96G069, 96G075-96G078,

96G135-96G140, 96G147,

96G148, 96G149, 96G150,

96G163, 96G167 included in Kit

571044

1

WIPER, stirring, models with fol-

lower plate - models 96G012,

96G014, 96G073, 96G082

included in Kit 571045

1

36 LABEL, brand 1

37 123741

FITTING, Zerk, grease, not

included on models

96G070-96G072,

96G079-96G081

1

40a 24E984

RESERVOIR, 2 liter, grease,

96G011-96G014,

96G027-96G029, 96G033,

96G034 included in Kit 571042,

571069

1

40b 16G021

RESERVOIR, 2 liter, oil,

96G070, 96G079, included in Kit

571179

1

40a 24B702

RESERVOIR, 4 liter, grease,

96G068, 96G073, 96G075,

96G082, 96G135, 96G137,

96G139, 96G147, 96G149,

included in Kit 571183

1

40b 16G020 RESERVOIR, 4 liter, oil,

96G071, 96G080 1

40a

RESERVOIR, 8 liter, grease,

96G069, 96G076, 96G136,

96G138, 96G140, 96G148,

96G150

1

40b

RESERVOIR, 8 liter, oil,

96G072, 96G081, included in Kit

571182

1

40a RESERVOIR, 12 liter, 96G077,

96G163 1

40a RESERVOIR, 16 liter, 96G078,

96G167 1

41

278139 SEAL, follower plate, 2 liter mod-

els 96G012, 96G014 1

16F472 SEAL, follower plate, 4 liter mod-

els 96G073, 96G082 2

Ref Part Description Qty

42

PLATE, follower, 2 liter models

96G012, 96G014 1

PLATE, follower, 4 liter models

96G073, 96G082 1

43

ROD, follower plate, 2 liter mod-

els 96G012, 96G014 1

ROD, follower, 4 liter models

96G073, 96G082

44

SPRING, compression, 2 liter

models 96G012, 96G014 1

SPRING, compression, 4 liter

models 96G073, 96G082 1

45† 24D838

BAFFLE, low level, 2 liter models

96G011, 96G013, 96G033,

96G034

1

†24E246

BAFFLE, low level, 4 liter models

96G068, 96G075, 96G147,

96G149

1

†24F836

BAFFLE, low level, 8 liter models

96G069, 96G076, 96G148,

96G150

1

†24F923

BAFFLE, low level, 12 liter mod-

els 96G077 1

†24F924

BAFFLE, low level, 16 liter mod-

els 96G078, 96G167 1

57 117156

BEARING, sleeve, models

96G011-96G014,

96G033-96G034, 96G068,

96G069, 96G073,

96G075-96G078, 96G082,

96G147-96G150, 96G163,

96G167

1

58196548

LABEL, models 96G013,

96G014, 96G029,

96G075-96G082, 96G139,

96G140

1

60 16D984

WASHER, low level, models

96G011-96G014,

96G033-96G034, 96G068,

96G069, 96G073,

96G075-96G078, 96G082,

96G147-96G150, 96G163,

96G167

2

Ref Part Description Qty

Parts

332298B 37

 Replacement Danger and Warning labels, tags and

cards are available at no cost.

 Also order Ref 27, Part No. 123025 and Ref 60, Part

No. 16D984

‡ For Pro Models Only - Also order Ref 31, Part No.

119228 and Ref 34, Part No. 16A578

† Also order Ref. 57, Part No. 117156 when ordering

this part.

61

RESERVOIR, mid-section, 8 liter

models 96G069, 96G072,

96G076, 96G081, 96G136,

96G138, 96G140, 96G148,

96G150

1

RESERVOIR, mid-section, 12

liter models 96G077, 96G163 2

RESERVOIR, mid-section, 16

liter models 96G078, 96G167 3

62

ADAPTER, reservoir, models

96G068, 96G069,

96G071- 96G073, 96G075-

96G078, 96G080-96G082,

96G135-96G140,

96G147-96G150, 96G163,

96G167

1

66 126417

NUT, oil, models 96G070,

96G071, 96G072, 96G079,

96G080, 96G081

67 24N806

FLOAT, oil, models 96G070,

96G071, 96G072, 96G079,

96G080, 96G081

200

126217

CABLE,15 ft (4.5 m), SOOW

w/7pos, 3 pin, 90 deg (See Wir-

ing Diagram, page 14)

1

126218

CABLE, 15 ft (4.5 m), SOOW w/7

pos, 5 pin, 90 deg, (See Wiring

Diagram, page 15)

1

126219

CABLE, 20 ft (6.1 m), SOOW,

w/7 pos, 5 pin, 90 deg, (See Wir-

ing Diagram, page 15)

1

126220

CABLE, 30 ft (9.1m) SOOW, w/7

pos, 5 pin, 90 deg, (See Wiring

Diagram, page 15)

16U790 CABLE, DIN, bare, (See Wiring

Diagram, page 12) 1

201

124300

CABLE, M12, 15 ft., 4 wire,

straight male to flying leads (See

Wiring Diagram, page 16)

1

124333

CABLE, M12, 15 ft., 4 wire,

straight male to female (See Wir-

ing Diagram, page 16)

1

202

124301 CONNECTOR, Eurofast, fem,

straight, 4 Pin 1

124594 CONNECTOR, Eurofast, 4 Pin

(see wiring diagram, page 17) 1

124595 CONNECTOR, Eurofast, 5 Pin

(see wiring diagram, page 17) 1

Ref Part Description Qty

Parts

38 332298B

Pressure Relief Valves

Important Information regarding Pressure Relief

Valve 16C807.

 Pressure Relief Valve 16C807 can only be used on

the G3 Pump. It is not intended for use with any other

products.

The pressure relief valve uses a

pressure adjustment screw (a) to

set the pressure release point. It

is not intended as a way to

relieve pressure during normal

operation, but as a protective

measure in the event there is an

unintended pressure increase in

the system. Do not use this pres-

sure relief valve a means of

relieving pressure in day-to-day,

normal cycle operation.

The pressure adjustment screw

will require periodic adjustments.

Whenever the valve is set/adjusted (after the set point is

found) it is important to ensure that the valve is not bot-

tomed out and there is at least 1/2 turn of adjustment

remaining. This is determined by turning the screw (a)

1/2 turn and then back turning it out again.

NOTE: Turning adjustment screw (a) clockwise

increases pressure.

Fuses

Installation and Repair Kits

Part Description Qty

16C807

VALVE, pressure relief, 500-3500 psi

(3.44 MPa, 34.4 bar - 24.1 MPa, 241

bar), Set pressure 3000 psi + 10%

(20.68 MPa, 206.8 bar + 10%)

Included in Kit 571028, 571071

1

563156 VALVE, pressure relief, 750 psi (5.17

MPa, 51.71 bar) 1

563157 VALVE, pressure relief, 1000 psi

(6.89 MPa, 68.95 bar) 1

563158 VALVE, pressure relief, 1500 psi

(10.34 MPa, 103.42 bar) 1

563159 VALVE, pressure relief, 2000 psi

(13.78 MPa, 137.89 bar) 1

563160 VALVE, pressure relief, 2500 psi

(17.23 MPa, 172.36 bar) 1

563161 VALVE, pressure relief, 3000 psi

(20.68 MPa, 206.84 bar) 1

a

ti15644

b

a = adjustment screw

b = locking nut

Part Description Qty

571039 FUSE, 12 volt DC 1

571040 FUSE, 24 volt DC 1

Kit No. Description

Manual

Number

571026 KIT, output union, 3 pump 3A0523

571063 KIT, output union, 2 pump

571028

KIT, return to reservoir NPT,

includes pressure relief valve

16C807 3A0525

571071

KIT, return to reservoir BSPP,

includes pressure relief valve

16C807

571030 KIT, remote manual run, 12 volt

DC

3A0528

571031 KIT, remote manual run, 24 volt

DC

571032 KIT, remote manual run, 12 volt

DC, with cable

571033 KIT, remote manual run, 24 volt

DC with cable

571036 KIT, cover with “G” label NA

571041 KIT, pump element, includes Ref

17, 18, 33 3A0533

571042 KIT, repair, 2 liter reservoir,

includes Ref 13, 36, 40

3A0534

571069

KIT, repair, 2 liter reservoir, for

models with follower plate,

includes Ref 13, 36, 40

571044

KIT, replacement, paddle, 2 liter,

for models without follower plate,

includes Ref 13, 16, 35, 57

3A0535

571045

KIT, replacement, paddle, 2 liter,

for models with follower plate,

includes Ref 13, 16, 35,40a, 42,

57

571046

KIT, replacement, paddle, 4-16

liter, for models without follower

plate, includes Ref 13, 16, 35, 57

571047

KIT, replacement, paddle, 4 liter,

for models with follower plate,

includes Ref 13, 16, 35, 57

Parts

332298B 39

571058 KIT, output adapter, NPT 3A0522

571070 KIT, output, adapter, BSPP

571060 KIT, fill, zerk, leakproof NA

571179 KIT, repair, reservoir oil, 2 liter

models, includes Ref 13, 36, 40b

3A0534

571182 KIT, repair, reservoir, oil 4 liter

models, includes Ref 13, 36, 40b

571183

KIT, repair, reservoir, grease, 4

liter models, includes Ref 13, 36,

40b

Kit No. Description

Manual

Number

Technical Data

40 332298B

Technical Data

A

Dimensions

Maximum Working Pressure 5100 psi (35.1 MPa, 351.6 bar)

Power

100-240 VAC 88 - 264 VAC; 0.8 A current, 90 VA Power, 47/63 Hz,

Single phase, inrush/locked rotor, max 40A (1ms)

12 VDC 9 - 16 VDC; 5 A current, 60 W, inrush/locked rotor 12 A

24 VDC 18 - 32 VDC; 2.5 A current, 60 W, inrush/locked rotor 6 A

Fluid

Grease Models Grease NLGI 000 - #2

Oil Models At least 40 cSt oil.

Pumps Up to 3

Pump Output 0.12 in.3 (2 cm3) / minute per outlet - 2 spacers

0.18 in.3 (3 cm3) / minute per outlet - 1 spacer

0.25 in.3 (4 cm3) / minute per outlet - 0 spacers

Pump Outlet 1/4-18 NPSF. Mates with 1/4-18 NPT male fittings

Reservoir Size 2, 4, 8, 12, 16 Liters

IP Rating IP69K

Ambient Temps -40°F - 158°F (-40°C to 70°C)

Weight (Dry - includes power cord and plug)

Without follower plate 13.3 lbs (6.03 kg)

With follower plate 14.2 lbs (6.44 kg)

Wetted Parts nylon 6/6 (PA), trogamid T5004-060, zinc plated steel,

carbon steel, alloy steel, stainless steel, nitrile rubber

(buna-N), bronze, nickel plated alnico, chemically lubri-

cated acetal, aluminum, PTFE, Grillamid

Sound Data <60 dB

Model Height Width Depth

Inches cm Inches cm Inches cm

2L 13.25 33.65 8.00 20.32 9.00 22.86

4L 14.50 36.83 9.25 23.50 10.00 25.40

8L 18.50 47.00 9.25 23.50 10.00 25.40

12L 23.00 58.42 9.25 23.50 10.00 25.40

16L 27.50 69.85 9.25 23.50 10.00 25.40

Technical Data

332298B 41

Mounting Pattern

(For correct mounting configuration, choose either Option 1 or Option 2). See P/N 126916 template.

FIG. 24

0.367inch

9.3 mm

2x Ø 0.366 inch

9.3 mm

3.544 inch

90.0 mm

7.087 inch

180.0 mm

1.180 inch

30.0 mm

3.268 inch

83.0 mm

0.722 inch

18.3 mm

2x Ø 0.366 inch

9.3 mm

3.189 inch

81.0 mm

6.378 inch

162.0 mm

3.740 inch

95.0 mm

0.708 inch

18.0 mm

Option 1

Option 2

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

For patent information, see www.graco.com/patents.

Original instructions. This manual contains English. MM 332298

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Copyright 2013, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

revised April 2014

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in

material and workmanship on the date of sale to the original purchaser for use. 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. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written

recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty

installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of

non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with

structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or

maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of

the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned

to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs

will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT

LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy

(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or

consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT

MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to

the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these

warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or

the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the

negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,

given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la

rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite

de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.

Phone: 612-623-6928 or Toll Free: 1-800-533-9655, Fax: 612-378-3590