Graco 332291B User's Manual
Contents
1. b Fr A l fi 4 1 1 i n MA it f A Di AA S IE WA i i A 111 A myi A N T t i i li A hy P IH I WI PILLIL T TI ATA ita n TT DANN LU OL UHR Il IT AS MN Li il j i i 7 i i i d A i if i Y Wath iy D f i 1 n i yr i i d f LA WX UP JA A TAF VA F y Low Level Oil Models Only 67 gt A Torque to 4 in Ibs 0 45 N m 4 A A Torque to 30 in Ibs 3 4 N m A Torque to 50 in Ibs 5 6 N m 332291B 27 Parts Parts al Por mun Tay Ae ree Bein a LIN low level models DEN ssec Spp AUSI Bis 96G003 96G008 96G038 278142 COVER bottom with seal EE 96G044 96G045 96G048 2 8136 96G049 96G053 115477 SCREW mach toxpanhd mach torx SCREW mach toxpanhd hd 96G055 96G058 96G062 RECT RING included in kit 187 LERH 571042 571069 571179 nji 96G18 O RING 258 included in Kit a PARE p A 13 124396 571042 571044 571045 571069 96G044 96G045 96G048 27 96G179 96G182 96G184 5 1179 123025 96G049 96G053 96G055 96G058 96G062 PADDLE stirring 2 Liter models bd EREDE EA EA without follower plate models 966000 966001 966002 WIPER stirring models without 966003 966005 966007 follower plate models 966000 9666182 included in Kit 571044 966001 966002 966003 PADDLE stirring 4 Liter models 35 96G005 96G007 1 without follower plate models 96G038 96G045 9660482. 96G038 96G040 96G042 96G049 96G055 96G058 96G044 96G048 96G055 96G171 96G172 96G182 96G179 966182 96G184 966187 966184 966184 included in Kit 571044 PADDLE stirring 8 Liter models WIPER stirring models with fol without follower plate models lower plate models 966006 96G039 96G041 96G043 96G008 96G053 96G062 96G045 96G049 96G056 96G179 966187 included in Kit 6 PADDLE stirring 12 Liter models 9 1045 without follower plate model ael LABEL brand 96G057 96G171 PADDLE stirring 16 Lit Jel FITTING zerk grease not without Ioe d T 37 123741 included on models 96G058 96G172 96G050 96G052 96G059 96G061 TE RESERVOIR 2 liter grease e E gli kill 24E984 96G000 96G008 96G182 96G006 96G008 included in Kit Guess Lor Odes 21989 571045 40b 16G021 RESERVOIR 2 liter oll 96G050 1 E 966059 included in Kit 571179 PADDLE stirring 4 liter models with follower plate models RESERVOIR 4 liter grease 96G053 96G062 96G179 96G038 96G040 96G042 PUMP ei AASA KE 40a 24B702 966044 966048 966053 KAIA ee d d ud 96G055 96G062 96G179 96G184 included in Kit 571183 SPACER stroke adjust included 16F368 in Kit 571041 40b 16G020 RESERVOIR 4 liter oil 96G051 1 96G060 278145 PLUG pump 3 4 16 28 332291B Parts Description Description RESERVOIR 8 liter grease LABEL models 96G002 96G007 96G039 96G041 96G043 96G008 96G042 96G043 96G045 96G049 96
3. Graco reserves the right to make changes at any time without notice For patent information see www graco corypatents Original instructions This manual contains English MM 332291 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
4. 12 Liter Models Part Numbers Model Number 96G057 G3 G ACNC 120A00 LD000000 966171 G3 G 24NC 120000 00C00000 16 Liter Models Part Numbers Model Number 96G058 G3 G ACNC 160A00 LD000000 96G172 G3 G 24NC 160000 00C00000 Part Model Numbers 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 Other pump configurations are available that are not documented in this manual Contact Graco Customer Service or your local Graco distributor for assistance Code Sample a a b b G3 G Identifies pump as being a G3 G Grease G3 A Identifies pump as being a G3 A Oil Code aa Power Source e 12 12 Volts DC e 24 24 Volts DC e AC 100 240 Volts AC Code bb Operation Control e NC No Controller Code cc Reservoir Capacity Liters e 2L 2 Liters e 4L 4 Liters e 8L 8 Liters e 12 12 Liters e 16 16 Liters Code d Follower Plate Installed e F Follower Plate Installed e 0 No Follower Plate Code e Low Level Option e A External Low Level e 0 No Low Level monitoring Code ff Options e 00 No Options 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 L Low Level O Not populated Fic 1 332291B
5. 24 volt DC NO 24M479 NPT DEU 3A0526 KIT vent valve 115 VAC NO 24M480 NPT DIN 5 1071 24N182 KIT vent valve 230 VAC 571036 KIT cover with G label NA KIT pump element includes Ref 571041 17 18 33 3A0533 KIT repair 2 liter reservoir 971042 includes Ref 13 36 40 KIT repair 2 liter reservoir for models with follower plate includes Ref 13 36 40 KIT replacement paddle 2 liter for models without follower plate includes Ref 13 16 35 57 KIT replacement paddle 2 liter for models with follower plate includes Ref 13 16 35 40a 42 57 KIT replacement paddle 4 16 liter for models without follower plate includes Ref 13 16 35 57 KIT replacement paddle 4 liter for models with follower plate includes Ref 13 16 35 57 571058 KIT output adapter NPT A0522 571070 KIT output adapter BSPP 571060 KIT fill zerk leakproof NA KIT repair reservoir oil 2 liter models includes Ref 13 36 40b 3A0534 KIT repair reservoir grease 4 571183 liter models includes Ref 13 36 3A0534 5 1069 5 1044 5 1045 3A0535 5 1046 5 1047 CO 40b S N S Parts 31 Technical Data Technical Data Maximum Working Pressure Power 100 240 VAC 12 VDC 24 VDC Outputs Low Level Dry Contact Contact Rating Switch Rating Switching Current Carry Current Fluid Grease Models Oil Models Pumps Pump Output Pump Outlet
6. using a pneumatic or electric transfer pump to not pressurize and break the reservoir 19 Setup Models without a follower plate 1 Connect fill hose to inlet fitting FiG 14 FIG 14 2 Forhigher viscosity fluids start pump to rotate stir ring paddle during fill to prevent air pockets from forming in grease For models using an external controller start pump operation per your controller specifications 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 max fill line Fic 15 4 Remove fill hose Models with a follower plate 1 Connect fill hose to inlet fitting FiG 14 2 Forhigher viscosity fluids start pump to rotate stir ring paddle during fill to prevent air pockets from forming in grease 20 For models using an external controller start pump operation per your controller specifications 3 Fill reservoir with grease until seal of follower plate breaches the vent hole FiG 16 and the majority of air is expelled from the reservoir FIG 16 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 332291B Filling Oil Unit e Only use oil appropriate for your application auto matic dispensing and the equipment s operat
7. 0 366 inch 9 3mm 1 180 inch 30 0 mm 3 3 268 inch 83 0 mm 3 544 inch 90 0 mm Option 2 0 722 inch 6 378 inch 18 3 mm 162 0 mm 2x 0 366 inch 0 708 inch 9 3 mm 18 0 mm 3 740 inch 95 0 mm 3 189 inch 81 0 mm FIG 22 332291B 33 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
8. Reservoir Size IP Rating Ambient Temps Weight Dry includes power cord and plug Without follower plate With follower plate Wetted Parts Sound Data Dimensions 5100 psi 35 1 MPa 351 6 bar 88 264 VAC 0 8 A current 90 VA Power 47 63 Hz Single phase inrush locked rotor max 40A ims 9 16 VDC 5 A current 60 W inrush locked rotor 12 A 18 32 VDC 2 5 A current 60 W inrush locked rotor 6 A 10 Watts Maximum 200 VDC Maximum 0 5 A Maximum 1 2 A Maximum Grease NLGI 000 2 At least 40 cSt oil Up to 3 0 12 in 2 cm minute per outlet 2 spacers 0 18 in 3 cm minute per outlet 1 spacer 0 25 in 4 cm minute per outlet 0 spacers 1 4 18 NPSF Mates with 1 4 18 NPT male fittings 2 4 8 12 16 Liters IP69K 40 F 158 F 40 C to 70 C 13 3 Ibs 6 03 kg 14 2 Ibs 6 44 kg 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 60 dB 13 25 33 65 2032 900 NEM NE 14 50 36 83 2350 1000 2540 8L 1850 47 00 2350 1000 25 40 23 00 58 42 23 50 10 00 25 40 27 50 69 85 23 50 10 00 25 40 32 332291B Technical Data Mounting 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 3mm 180 0 mm 2x
9. 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 r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es 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 All written and visual data contained in this document reflects the latest product information available at the time of publication
10. Black Connector on Housing Connector on Cable 4 4 1 2 2 1 3 Example Wiring Diagram FIG 3 12 332291B Installation 12 VDC 24VDC Power DIN DC 15 foot Part No 16U790 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 and Related Wire Color Fic 5 Pi PmName Coir VDC White 1 Not Used Not Used 4 Not Used M Connector on an Connector on a Example Wiring Diagram sid Wiring Diagram Ignition Switch 12V pump 7 5A Graco kit 571039 24V pump 4A Graco kit 571040 FIG 5 332291B 13 Installation 12VDC 24VDC Power CPC DC 15 foot Part No 126217 Pin and Related Wire Color Fic 6 Pim PinName Coto 2 Black 6 NotUsed NotUsed Connector on Housing Connector on Cable 2 3 12V pump 7 5A Graco kit 571039 24V pump 4A Graco kit 4571040 FiG 6 14 332291B Installation NM Low Level Outputs See Low Level Output Option page 22 for functional description See Technical Data page 32 for ratings ENO 3 LNO Connector on Connector on SN Example Example Wiring Diagrams Diagram FIG 7 332291B 15 Installation Part No 124333 Cabl
11. ENT HAZARD Over pressurization can result in equipment rupture and serious injury e 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 e Use only compatible water based solvents to clean plastic structural or pressure containing parts e 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 e Keep clear of moving parts e Do not operate equipment with protective guards or covers removed e 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 e Protective eyewear and hearing protection e Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer 6 332291B Installation Installation Grounding ND The eguipment must be gro
12. G056 96G055 96G062 96G179 96G187 96G187 RESERVOIR 8 liter oil 966052 WASHER low level models 96G061 included in Kit 571182 96G003 96G008 RESERVOIR 12 liter 96G057 96G077 96G171 96G044 96G045 96G048 96G049 96G053 40a a 96G055 96G058 96G062 40 96G033 96G038 RESERVOIR 16 liter 96G058 96G172 E 96G043 96G045 96G049 m 96G006 96G008 _ Me eer RESERVOIR mid section 12 liter 2 A P te ae models 96G057 96G171 TAM E RESERVOIR mid section 16 liter 3 96G053 96G062 96G179 96G038 96G045 96G048 62 1 1 1 278139 SEAL follower plate 2 liter models 1 EUM iil 966006 966008 41 RESERVOIR mid section 8 liter 2 1 SPRING compression 2 liter 1 96G049 96G051 96G053 models 96G006 96G008 96G055 96G057 96G058 44 J J J SPRING compression 4 liter models 96G053 96G062 96G179 96G187 96G060 96G062 96G171 BAFFLE low level 2 liter models 45t 24D838 96G003 96G005 96G007 1 s NUT oil models 966050 96G172 966179 966184 966182 126417 96G051 96G052 96G059 BAFFLE low level 4 liter models 96G060 96G061 T 24E246 96G044 96G048 96G055 FLOAT oil models 96G050 966G184 67 24N806 96G051 96G052 96G059 BAFFLE low level 8 liter models 96G060 966061 T 24F836 96G045 96G049 96G052 CABLE 15 ft 4 5 m SOOW 96G056 96G061 126217 w 7pos 3 pin 90 deg See Wiring 200 96G057 CABLE DIN bare See Wiring BAFFLE low level 16 liter models Diag
13. Instructions GG g GRACO G3 Standard Automatic Lubrication Pump as 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 e Read all warnings and instructions in this manual Save these instructions TI14705 lj Conforms to ANSI UL 73 c US Certified to CAN CSA Std 22 2 No 68 09 Intertek 3132066 PROVEN QUALITY LEADING TECHNOLOGY Contents Part Model Numbers 3 2 bier Models 232m uw dr debes d antt ret Sabes 3 4 Liter Models 0 3 S Liter Models 42 3 44 othe eo ode Fh eee 3 12 Liter Models 0 3 16 Liter Models 0 3 Understanding the Model Number 4 Warnings urbs adt pex uos eR oie ee deere E 5 In stallallOn irti sux Ren a Rue hi rj ee 7 Typical Installation 8 Choosing an Installation Location 9 System Configuration and Wiring 10 SEUD ss ana ed m e Rr dc opa aei lead 18 Connecting to Auxiliary Fittings 18 Setting Pump Outlet Volume 19 Loading Grease 19 Filling OU IE serico i ertt de M eme od 21 FANG eter rp 21 No Controller Operation 22 Trouble
14. Warnings 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 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 e Do not operate the unit when fatigued or under the influence of drugs or alcohol e 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 equ
15. am page 17 Pressure Relief Valves Important Information regarding Pressure Relief Valve 16C807 m 571039 FUSE 12 volt DC Pressure Relief Valve 16C807 can only be used on 1 the G3 Pump lt is not intended for use with any other 971040 FUSE 24 volt DC E products The pressure relief valve uses a a pressure adjustment screw a to ji set the pressure release point It X 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 ti1564 a adjustment screw locki t The pressure adjustment screw sa A will reguire periodic adjustments Whenever the valve is set adjusted after the set point is found itis 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 30 332291B Installation and Repair Kits Manual Kit No Description Number 57102 KIT output union 3 pump 3A0523 O 57106 KIT output union 2 pump KIT return to reservoir NPT includes pressure relief valve 16C807 571028 KIT return to reservoir BSPP E includes pressure relief valve 16C807 KIT vent valve 12 volt DC NO 24M478 NPT DEU KIT vent valve
16. d into an outlet that is properly installed and grounded in accordance with all local codes and ordinances e when repair or replacement of the power cord or plug is required do not connect the grounding wire to either flat blade terminal 10 Fuses NOTICE Fuses user supplied are required on all DC mod els To avoid equipment damage e 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 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 Input Voltage 12 VDC 7 5A 5 1039 24 VDC 571040 Recommendations for Using Pump in Harsh Environments e Use pump with CPC style power cable e 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 e Use a corrosion preventative electrical grease on all contacts 332291B Installation Wiring and Installation Diagrams The following Table identifies the wiring and installation diagrams for the cable included with the pump provided in this manual Diagram Power DIN DC ee a m 12 VDC 24VDC Power CPC DC 12 VDC 24VDC Low Level Outputs 332291B 11 Installation Power DIN AC 15 foot Part No 16U790 AC Pin and Related Wire Color Fic 3 Color
17. e Always use two wrenches working in opposite directions when connecting anything to pump element or auxiliary fittings See FiG 12 for an example Torque pump element fittings to 50 in lbs 5 6 Nem When connecting pump element into housing torque to 50 in Ibs 5 6 Nem Pressure Relief Valves 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 e 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 27 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 30 332291B Setting Pump Outlet Volume NOTE e Before making any adjustments to pump volume Relieve Pressure following procedure on page 18 e Only use Graco supplied spacers to control output volume e 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 Usea wrench to turn pump element counter clock wise to loosen Do not remove entire pump element Only back pump element out enough to allow spacer to be slid on or off 2 f
18. e Pin Out M12 Wire Colors Cable Pin Out Female End View Male End View Fic 8 Part No 124300 Field Wireable Pin Out M12 Wire Colors Color Brown White Blue Field Wireable Pin Out Female End View 4 FiG 9 332291B Part No 124594 4 Pin Eurofast Field Wireable Connector FiG 10 332291B Installation Part No 124595 5 Pin Eurofast Field Wireable Connector Fic 11 17 Setup Setup Pressure Relief Follow the Pressure Relief Procedure whenever TN you see this symbol 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 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 18 Connecting to Auxiliary Fittings 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
19. e that a low level condition has been met the When the oil level has reached a low warning level ae eve trigger must be detected for 10 continuous sec PINS 3 and 4 close sending the signal to the controller that the fluid has reached a low level See Fic 21 for an illustration of a typical Low Level Out put response to low oil level Typical Low Level Output Response with Low Level Fluid in Oil Models Closed Contact Position Open Fic 21 332291B 23 Troubleshooting Troubleshooting SAA Problem Cause Solution EE NEN wiring Refer to Installation instructions Unit does not power on page 7 Tripped external fuse due to internal Contacts CudtomEHE ICE component failure Tripped external fuse due to pump Replace lubricant with pumpable ing non cold weather lubricant in lubricant rated for environmental cold weather 13 F 25 C conditions and application Unit does not power on DC models only Replace fuse Unit does not power on AC models Tripped internal power supply fuse Center mes CEOE SENEE only due to power supply failure Reservoir retaining tabs are Replace reservoir cracked or broken Reservoir is being pressurized Ensure vent hole is not plugged during filling Lubricant leaks past seal located on the bottom of the reservoir If problem persists contact Graco Customer Service or your local Graco distributor for assistance Unit not pumping during ON cycle Failed mo
20. ing temperature Consult with machine and lube manu facturer for details e The reservoir can be filled using a hand operated pump pneumatic pump or electric transfer pump e Do not overfill FIG 17 e Do not operate G3 without reservoir attached e Only use oils with viscosity at least 40 cSt FIG 17 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 18 NOTE When loosening pump element fitting do NOT loosen pump element Loosening pump element will change the output volume 332291B Setup a FIG 18 2 Only run pump until air is no longer dispensed with the lubricant coming out of element fitting FIG 19 NOS M SJ I fie um Mm S AN 4 m Y D ow ie EN A i be e M f r T T rl Hi gt ON E Eie 3 Tighten pump element fitting using two wrenches working in opposite directions FIG 18 21 No Controller Operation No Controller Operation The G3 Pump can be controlled using an external user supplied power source and controller Refer to the Typical Installation diagrams provided on page 8 for correct location of the required pump ground wire a
21. ipment 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 332291B 5 Warnings 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 e 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 EQUIPM
22. lations i e m EN 00 OO Lo 9o Injector Installations T pyy E gt s 8 H ol A Connected to fuse power F Proximity Switch Divider Installations B Pressure relief valve Not included reguired for each outlet Pressure switch Injector Installations user supplied See Parts page 30 G Vent valve Not included available from Graco See Parts D Series progressive divider valves Divider Installations page 31 Injectors Injector Installations H Return to reservoir E To lube points 332291B Installation Choosing an Installation Location ADA OOO AUTOMATIC SYSTEM ACTIVATION HAZARD If the system is eguipped with has an automatic timer user supplied that activates the pump lubrication system when power is connected or when exiting the programming function unexpected activation of the system could result in serious injury including skin injection and amputation Before you install or remove the lubrication pump from the system disconnect and isolate all power supplies and relieve all pressure 332291B 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 33 NOTE The two mounting hole layouts provided in the Technical Data section show the only cor rect installation patte
23. nd fuses NOTE e When using an external power source and control ler Pump ON Run Time should be set for no lon ger than 30 minutes e n most cases Pump OFF Rest Time should be twice as long as Pump ON Run time If alternative ON OFF times are required contact Graco Cus tomer Service for assistance Low Level Output Option Some G3 pumps without controllers include a Low Level Output Option It can be configured with an M12 con nector in code location G or with a DIN connector in code location K See Understanding the Model Num ber page 4 The low level signal is monitored across PINS 3 and 4 For PIN 3 and 4 locations and wiring information the Low Level Outputs diagram page 15 NOTE A low level warning is triggered when the con troller detects PINS 3 and 4 have momentarily closed Grease Pumps When the grease level has reached a low warning level PINS 3 and 4 momentarily close 1 time per paddle rev olution sending the signal that the fluid has reached a low level to the controller To ensure that a low level condition has been met 3 or more low level triggers must be detected within 1 minute or less See FiG 20 for an illustration of a typical Low Level Out put response to low grease level Typical Low Level Output Response with Low Level Fluid in Grease Models Closed Contact Position Open FIG 20 22 200 ms di die 332291B No Controller Operation Oil Pumps To ensur
24. needed remove or insert spacers to achieve required pump output volume A tool may be needed to facilitate removal Pump volume control is set using either no 0 spac ers 1 or 2 spacers FIG 13 Do not use more than 2 spacers to adjust output vol ume Output Volume Minute No Spacers 0 12 AO 3 oe s e The amount of dispensed volume can vary depend ing on external conditions such as lubricant tem perature and back pressure from downstream connections e Use of these volume adjustment in conjunction with setting the ON time of the pump will allow for control of the output volume e Use these volume adjustments as a starting point and adjust as necessary to ensure desired lubrica tion dispense 332291B Setup 3 Tighten pump element fitting Torque fitting to 50 in Ibs 5 6 Nem Loading Grease To ensure optimal performance from the G3 e 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 e The reservoir can be filled using a hand operated pump pneumatic pump or electric transfer pump e Do not overfill FIG 15 e Do not operate G3 without reservoir attached e Always clean fitting D with a clean dry cloth prior to filling reservoir Dirt and or debris can damage pump and or lubrication system e Care must be used when filling the reservoir
25. ram page 12 96G058 BEARING sleeve models 96G003 96G008 966038 96G044 96G045 96G048 57 117156 96G049 96G053 96G055 96G058 96G062 96G179 96G182 96G184 96G187 332291B 29 Parts 212 NOTE Turning adjustment screw a clockwise me e Dein av increases pressure CABLE M12 15 ft 4 wire straight 124300 male to flying leads See Wiring Diagram page 16 CABLE M12 15 ft 4 wire straight 124333 male to female See Wiring Dia Part Description 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 VALVE pressure relief 750 psi 5 17 263156 MPa 51 71 bar E VALVE pressure relief 1000 psi 124595 Eurofast ma 263157 6 89 MPa 68 95 bar E GES wung dagran page 16 563168 VALVE pressure relief 1500 psi l 10 34 MPa 103 42 bar A Replacement Danger and Warning labels tags and cards are available at no cost 563159 VALVE pressure relief 2000 psi Al der Ref 27 Part No 123025 and Ref 60 Part E a EE can Also order Re Part No and Re Par l z No 16D984 563160 VALVE pressure relief 2500 psi 1 17 23 MPa 172 36 bar Also order Ref 57 Part No 117156 when ordering 563161 Ni E 3000 psi this part 0 68 a 206 ar Fuses 16C807 gram page 16 124301 CONNECTOR Eurofast fem straight 4 Pin 202 124594 CONNECTOR Eurofast 4 Pin see wiring diagr
26. rns 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 Installation System Configuration and Wiring 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 If the product is permanently connected e it must be installed by a qualified electrician or ser viceman e it must be connected to a grounded permanent wir ing system If an attachment plug is required in the end use application e it must be rated for the product electrical specifica tions e it must be an approved 3 wire grounding type attachment plug e it must be plugge
27. shooting 24 Maintenance ees 25 Parts 2 Liter Models 26 Parts A Liter and Larger Models 27 Parts eu Sees eats ee PS d eee see 28 Technical Data x t Adenia te serie 32 DIMENSIONS 539 3 s ea wee dee deo ao erp ees Al hot 32 Mounting Pattem 33 Graco Standard Warranty 34 Graco Information 34 2 332291B Part Model Numbers 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 Part Numbers Model Number 4 Liter Models Part Model Number Numbers 332291B 8 Liter Models Part Numbers Model Number 96G039 G3 G 12NC 8L0000 00C00000 96G041 G3 G 24NC 8L0000 00C00000 96G043 G3 G ACNC 8L0000 0D000000 96G045 G3 G 12NC 8LOA00 LOCO0000 96G049 G3 G 24NC 8LOA00 LOCO0000 96G052 G3 A 24NC 8LOA00 LOCO0000 96G056 G3 G ACNC 8LOA00 LDO00000 96G061 G3 A ACNC 8LOAO00 LDO000000 966187 G3 G ACNC 8LFAO0 0DOOLOOO
28. 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
29. tor Replace unit but external controller functions Air is trapped in the reservoir Add grease following Loading Follower plate is not going down between the follower plate and lubri Grease instructions page 19 cant Ensure air is purged Pump takes several minutes before Pumping non cold weather lubricant Add 1 stroke adjust spacer and it begins pumping at the highest in cold weather 13 F 25 C adjust lube cycle time to accommo pump volume setting no stroke date the difference in pump volume adjust spacers installed per stroke In an Injector System without sen Vent valve time needs to be config Adjust external vent valve control sor feedback unit does not vent ured time properly 24 332291B Maintenance 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 Monthly External Wiring Harness Verify external harnesses are secure 332291B 25 Parts 2 Liter Models Parts 2 Liter Models 40b Follower Plate iJ Models Only Low Level Grease Models Only i AN Torque to 4 in Ibs 0 45 N m L A Torque to 30 in Ibs 3 4 N m ie 4A Torque to 50 in Ibs 5 6 N m 26 332291B Parts 4 Liter and Larger Models Parts 4 Liter and Larger Models Follower Plate Models Only
30. unded 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 eguipped with a cord having an eguipment grounding conductor The wire with insulation having an outer surface that is green with or without yellow stripes is the grounding wire Component Identification 3 A Grease Models VN S m 4d Grease Models with Follower Plate 96GXXX G3 G 24NC 2LOAO00 LOCOO0000 FiG 2 Key A Reservoir H Power Sensor Panel both sides only one side shown B Adjustable Pump Element 1 included Can accommodate 3 Part Number Model Number example only shown see total page 4 Understanding the Model Number for details C Pressure Relief Valve Not included required for each outlet J Power Cord DIN shown Available from Graco See Parts page 30 K Follower Plate grease models only not available on all D Zerk Inlet Fill Fitting 1 included grease models only grease models E Pump Outlet Plug 2 included L Vent Hole for Follower Plate grease models only not F X Volume Control Spacers 2 included More spacers less available on all grease models output volume per stroke also see FIG 13 page 19 M Fill cap oil models only G Fuse DC models only Not included not shown Available from Graco See Parts page 30 332291B 7 Installation Typical Installation Divider Instal
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