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Installation 

10

3A6319E

Installation

Unpack

The pump module was carefully packaged for shipment

by Graco. When the package arrives, perform the fol

-

lowing procedure to unpack the units:
1. Inspect the shipping box carefully for shipping 

damage. Contact the carrier promptly if damage is 

discovered.

2. Unseal the box and inspect the contents carefully. 

There should not be any damaged parts.

3. Compare the packing slip against all items included 

in the box. Any shortages or other inspection 

problems should be reported immediately.

Choose an Installation Location

• Select a location that adequately supports the 

weight of the G3 pump and lubricant, as well as all 

plumbing and electrical connections.

• Refer to the mounting hole layouts provided in 

Mounting Bracket Dimensions

, page 21. No other 

installation configuration should be used.

• Use designated mounting holes and provided con

-

figurations only. 

• Use the five (5) fasteners (included) to secure the 

G3 pump to the mounting surface. Three (3) fasten

-

ers are used for the bottom bracket and two (2) fas

-

teners are used for the top bracket.

• Adjust top mounting bracket, if necessary, to align 

the bracket with the mounting surface (F

IG

. 5).

• Insert (user supplied) spacers if there is still a gap 

after adjusting the bracket.

System Wiring

Fuses

Fuse Kits are available from Graco. The table identifies 

the correct fuse to use for the input voltage and the cor

-

responding Graco Kit number.

Recommendations for Pump Usage in 

Harsh Environments

• 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.

NOTICE

To prevent equipment damage, observe precautions 

for handling electrostatic sensitive devices. Touch 

ground before handling pump. 

AUTOMATIC SYSTEM ACTIVATION HAZARD

If the system is equipped with 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 installation or removal of the lubrication pump 

from the system, disconnect and isolate all power 

supplies and relieve all pressure.

F

IG

. 5

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 current rating must be 

installed in line with the power entry to the 

equipment. 

Input Voltage

Fuse Value

Graco Kit No.

24 VDC

4 A

571040

Summary of Contents for 96G500

Page 1: ...or Professional Use Only Not approved for use in explosive atmospheres or hazardous classified locations Models see page 3 5100 psi 35 1 MPa 351 6 bar Maximum Pump Output Pressure Important Safety Ins...

Page 2: ...10 Wiring and Installation Diagrams 11 Setup 12 Pressure Relief Procedure 12 Connecting to Auxiliary Fittings 12 Pressure Relief Valves 12 Setting Pump Outlet Volume 13 Load Pump with Grease 13 Prime...

Page 3: ...3 Pump To help with understanding each component that makes up the Model Number see Under standing the Model Number page 4 The tables below shows the relationship between each Part Number and its rela...

Page 4: ...s being a G3 G Grease G3 A Identifies pump as being a G3 A Oil Code aa Power Source 24 24 Volts DC Code bb Operation Control NC No Controller Code cc Reservoir Capacity Liters 8L 8 Liters 12 12 Liters...

Page 5: ...d 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...

Page 6: ...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 r...

Page 7: ...f Valves page 20 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 9 pag...

Page 8: ...Progressive Divider Valve Key A Connected to fused power source B Pressure Relief Valve not included required for each outlet user supplied C Supply Hose user supplied D Series Progressive Divider Va...

Page 9: ...ed power source B Pressure Relief Valve not included required for each outlet user supplied C Supply Hose user supplied D Injectors E To lube points F Pressure Switch G Vent Valve not included availab...

Page 10: ...ed spacers if there is still a gap after adjusting the bracket System Wiring Fuses Fuse Kits are available from Graco The table identifies the correct fuse to use for the input voltage and the cor res...

Page 11: ...e pump Power DIN DC 15 foot Pin and Related Wire Color FIG 6 Low Level Outputs See Low Level Output Option page 15 for functional description See Dimensions page 21 for ratings Pins FIG 7 Pin Pin Name...

Page 12: ...and before cleaning checking or servicing the equipment FIG 8 NOTICE Do not attach unsupported equipment to auxiliary fit tings such as fill ports and pump element Attaching unsupported equipment to t...

Page 13: ...nt and adjust as necessary to ensure desired lubrica tion dispense Load Pump with Grease To ensure optimal performance from the G3 pump Only use NLGI 000 2 greases appropriate for the application auto...

Page 14: ...filled with lubricant The pump only requires priming the first time it is used or if it is allowed to run dry 1 Loosen pump element fitting FIG 11 NOTE When loosening the pump element fitting do not l...

Page 15: ...l Output Option The low level signal is monitored across PINS 3 and 4 For PIN 3 and 4 locations and wir ing information see the Low Level Outputs page 11 NOTE A low level warning is triggered when the...

Page 16: ...rds LCDs liquid crystal displays and other electronic components Recycle according to applicable regulations Do not dispose of electronic components with household or commercial waste Deliver remainin...

Page 17: ...Reservoir is being pressurized during filling Ensure vent port is not plugged If problem persists contact Graco Customer Service or your local Graco distributor for assistance Unit not pumping during...

Page 18: ...s 18 3A6319E Parts 43 36 6 44 30 31 16 10 22 40 42 24 5 27 26 25 41 29 1 3 21 20 23 32 4 2 42 45 8 Liter Model Reservoir for 12 Liter and Larger Models 20 21 12 10 See 8 Liter Model for all other part...

Page 19: ...guide 15L 1 ROD guide 20L 1 21 SPRING B compression 8L 1 SPRING A compression 12L 2 SPRING A compression 15L 2 SPRING B compression 20L 2 22 19B457 SEAL grease 16 mm id 1 23 NUT 1 24 Plate follower 1...

Page 20: ...on 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 1 563156 VAL...

Page 21: ...dth Depth Inches cm Inches cm Inches cm 8L 22 34 56 74 8 94 22 70 10 37 26 34 12L 27 34 69 44 8 94 22 70 10 37 26 34 15L 30 99 78 71 8 94 22 70 10 37 26 34 20L 37 09 94 21 8 94 22 70 10 37 26 34 Model...

Page 22: ...Switch Rating 200 VDC Maximum Switching Current 0 5 A Maximum Carry Current 1 2 A Maximum Fluid Grease NLGI 000 2 Pumps Up to 3 Pump Output 2 spacers per outlet 0 12 in 3 minute 2 cm3 minute 1 spacer...

Page 23: ...California Proposition 65 3A6319E 23 California Proposition 65 CALIFORNIA RESIDENTS WARNING Cancer and reproductive harm www P65warnings ca gov...

Page 24: ...t 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...

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