Graco 332305B, G3 Max Automatic Lubrication Pump Owner's Manual

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Graco 332305B, G3 Max Automatic Lubrication Pump Owner's Manual | Manualzz

Instructions

G3 Max Automatic

Lubrication Pump

332305B

EN

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.

3132066

Conforms to ANSI/UL 73

Certified to CAN/CSA

Std. 22.2 No 68-09

TI14705

2

Contents

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

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

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

8 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

12 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 4

16 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Understanding the Model Number . . . . . . . . . . . 5

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 9

Choosing an Installation Location . . . . . . . . . . . 10

System Configuration and Wiring . . . . . . . . . . . 11

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Connecting to Auxiliary Fittings . . . . . . . . . . . . . 23

Setting Pump Outlet Volume . . . . . . . . . . . . . . . 24

Loading Grease . . . . . . . . . . . . . . . . . . . . . . . . 24

Filling Oil Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Quick Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . 27

Max Model Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Control Panel Overview . . . . . . . . . . . . . . . . . . 28

Programming the Max Model . . . . . . . . . . . . . . 29

Pump OFF / REST Setup . . . . . . . . . . . . . . . . . 34

DMS ™ Models Only . . . . . . . . . . . . . . . . . . . . . 37

Operation / Data Log . . . . . . . . . . . . . . . . . . . . . . . 39

System Event Log . . . . . . . . . . . . . . . . . . . . . . . 39

Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Functional Summary . . . . . . . . . . . . . . . . . . . . . 42

Technical Summary . . . . . . . . . . . . . . . . . . . . . 44

Advanced Programming . . . . . . . . . . . . . . . . . . . . 45

Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Fault / Warning Scenarios . . . . . . . . . . . . . . . . . 57

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Parts - 2 Liter Models . . . . . . . . . . . . . . . . . . . . . . 65

Parts - 4 Liter and Larger Models . . . . . . . . . . . . . 66

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Mounting Pattern . . . . . . . . . . . . . . . . . . . . . . . . 74

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 76

Graco Information . . . . . . . . . . . . . . . . . . . . . . . 76

332305B

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 specific G3 Pump. To help you understand each component that makes up the Model Number see Understanding Your

Model Number, page 5. The tables below shows the relationship between each Part Number and its related Model

Number.

2 Liter Models

Part

Numbers

Model Numbers

96G017 G3-G-24MX-2L0L00-10CV00R0

96G018 G3-G-24MX-2LFL00-10CV00R0

96G019 G3-G-ACMX-2L0L00-1D0V0000

96G020 G3-G-ACMX-2LFL00-1D0V0000

96G021 G3-G-12MX-2L0L00-1DMVA2R3

96G023 G3-G-24MX-2L0L00-1DMVA2R3

96G024 G3-G-24MX-2LFL00-1DMVA2R3

96G025 G3-G-ACMX-2L0L00-1DMVA2R3

96G026 G3-G-ACMX-2LFL00-1DMVA2R3

96G030 G3-G-12MX-2L0L00-10C00000

96G031 G3-G-24MX-2L0L00-10C000R0

96G032 G3-G-ACMX-2L0L00-1D000000

96G035 G3-G-12MX-2L0L05-10CV0000

96G036 G3-G-24MX-2L0L05-10CV0000

96G037 G3-G-ACMX-2L0L00-1D00A000

96G098 G3-G-12MX-2L0L00-UDMVA1R2

96G107 G3-A-24MX-2L0L00-1DMVA2R3

96G110 G3-G-24MX-2L0L00-UDMVA1R2

96G115 G3-G-24MX-2LFL00-UDMVA1R2

96G122

G3-A-ACMX-2L0L00-1DMVA2R3

96G125 G3-G-ACMX-2L0L00-UDMVA1R2

96G132 G3-G-ACMX-2LFL00-UDMVA1R2

96G174 G3-A-ACMX-2L0L00-UDMVA1R2

96G178 G3-G-24MX-2L0L00-0D00A100

4 Liter Models

Part

Numbers

Model Numbers

96G088 G3-G-24MX-4L0L00-10CV00R0

96G090 G3-G-24MX-4LFL00-10CV00R0

96G092 G3-G-ACMX-4L0L00-1D0V0000

96G094 G3-G-ACMX-4LFL00-1D0V0000

96G096 G3-G-12MX-4L0L00-1DMVA2R3

96G099 G3-G-12MX-4L0L00-UDMVA1R2

96G103 G3-G-24MX-4L0L00-1DMVA2R3

96G108 G3-A-24MX-4L0L00-1DMVA2R3

96G111

G3-G-24MX-4L0L00-UDMVA1R2

96G113 G3-G-24MX-4LFL00-1DMVA2R3

96G116 G3-G-24MX-4LFL00-UDMVA1R2

96G118 G3-G-ACMX-4L0L00-1DMVA2R3

96G123 G3-A-ACMX-4L0L00-1DMVA2R3

96G126 G3-G-ACMX-4L0L00-UDMVA1R2

96G128 G3-G-ACMX-4LFL00-1DMVA2R3

96G133 G3-G-ACMX-4LFL00-UDMVA1R2

96G141 G3-G-12MX-4L0L00-10C00000

96G143 G3-G-24MX-4L0L00-10C00000

96G145 G3-G-ACMX-4L0L00-1D000000

96G151 G3-G-12MX-4L0L05-10CV0000

96G153 G3-G-12MX-4L0L05-U0CV0100

96G155 G3-G-24MX-4L0L05-10CV0000

96G157 G3-G-24MX-4L0L05-U0CV0100

96G159 G3-G-12MX-4L0L05-00C0010M

96G160 G3-G-24MX-4L0L05-00C0010M

96G161 G3-G-12MX-4L0L05-U0C0010M

96G162 G3-G-24MX-4L0L05-U0C0010M

96G175 G3-A-ACMX-4L0L00-UDMVA1R2

96G181 G3-G-24MX-4L0L03-00C00100

96G183 G3-G-ACMX-4L0L00-1D00A000

96G188 G3-A-24MX-4L0L05-U0C0010M

332305B 3

4

Part / Model Numbers

8 Liter Models

Part

Numbers

Model Numbers

96G089 G3-G-24MX-8L0L00-10CV00R0

96G093 G3-G-ACMX-8L0L00-1D0V0000

96G097 G3-G-12MX-8L0L00-1DMVA2R3

96G100 G3-G-12MX-8L0L00-UDMVA1R2

96G104 G3-G-24MX-8L0L00-1DMVA2R3

96G109 G3-A-24MX-8L0L00-1DMVA2R3

96G112

G3-G-24MX-8L0L00-UDMVA1R2

96G119

G3-G-ACMX-8L0L00-1DMVA2R3

96G124 G3-A-ACMX-8L0L00-1DMVA2R3

96G127 G3-G-ACMX-8L0L00-UDMVA1R2

96G142 G3-G-12MX-8L0L00-10C00000

96G144 G3-G-24MX-8L0L00-10C00000

96G146 G3-G-ACMX-8L0L00-1D000000

96G152 G3-G-12MX-8L0L05-10CV0000

96G154 G3-G-12MX-8L0L05-U0CV0100

96G156 G3-G-24MX-8L0L05-10CV0000

96G158 G3-G-24MX-8L0L05-U0CV0100

96G176 G3-A-ACMX-8L0L00-UDMVA1R2

96G177 G3-G-24MX-8L0L05-00C0010M

96G186 G3-A-12MX-8L0L05-U0C0010M

12 Liter Models

Part

Numbers

Model Numbers

96G105 G3-G-24MX-120L00-1DMVA2R3

96G120 G3-G-ACMX-120L00-1DMVA2R3

96G164 G3-G-24MX-120L05-10CV00000

96G165 G3-G-24MX-120L05-U0CV0100

16 Liter Models

Part

Numbers

96G106

Model Numbers

G3-G-24MX-160L00-1DMVA2R3

96G121 G3-G-ACMX-160L00-1DMVA2R3

96G166 G3-G-ACMX-160L00-1D0V0000

96G168 G3-G-24MX-160L05-10CV0000

96G169 G3-G-24MX-160L05-U0CV0100

96G185 G3-G-24MX-160L05-U0C0010M

332305B

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: Some pump configurations are not available. Contact Graco Customer Service or your local Graco distributor for assistance.

Code Sample:

G 3 - G M X a a b b c c d e f f g h i j k m n p

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

• MX = Max (Cycle) 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

• 03 = Powered Alarm Contact

• 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 F IG . 1 for these locations.

• C = CPC

• D = DIN

• 1, 2, 3 = Sensor Number

• R = Remote Manual Run

• M = Machine Count

• A = Alarm Output

• V = Vent Valve

• 0 = Not populated

• U = USB Port

DMS TM Models h k m i g n p j

F IG . 1

332305B 5

6

Warnings

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. When these symbols appear in the body of this manual, refer back to these warnings. Additional, product-specific warnings may be found 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 manufacturer’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.

332305B

332305B

Warnings

WARNING

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Do not point dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

PRESSURIZED EQUIPMENT HAZARD

Over-pressurization can result in equipment rupture and serious injury.

• A pressure relief valve is required at each pump outlet.

• Follow Pressure Relief Procedure in this manual before servicing.

PLASTIC PARTS CLEANING SOLVENT HAZARD

Many solvents can degrade plastic parts and cause them to fail, which could cause serious injury or property damage.

• Use only compatible water-based solvents to clean plastic structural or pressure-containing parts.

• See Technical Data in this and all other equipment instruction manuals. Read fluid and solvent manufacturer’s MSDSs and recommendations.

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing 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

7

Installation

Installation

Grounding

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.

Component Identification

N

A

L

M

Oil Models

DMS TM Models

C

P

I

Grease Models

Grease Models with Follower

Plate

E

D

H

F

K

J

96GXXX

G3-G-24NC-2L0A00-L0C00000

F IG . 2:

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 71.)

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 F

IG

. 15, page 24)

G Fuse (DC models only - Not included, not shown. Available from Graco. See Parts, page 71.)

H Control Panel

8

B

I Power / Sensor Panel (both sides; only one side shown)

J Part Number / Model Number example only shown, (see

pages 5, 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)

P USB Port (DMS

Models only)

332305B

Installation

Typical Installation

Divider Installations

B

D

E

A

C F

Injector Installations

E

H

B

F

D

G

A

C

A Connected to fuse / power

B Pressure relief valve (Not included/required for each outlet - user supplied. See Parts, page 71)

C - Cycle indicator sensor cable (Divider Installations)

- Pressure switch cable (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)

332305B

G Vent valve (Not included / available from Graco. See

Parts, beginning on page 67.)

H Return to reservoir

9

Installation

Choosing an Installation Location

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.

• 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 74.

NOTE: The two mounting hole layouts provided in the Technical Data section show the only correct 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 follower 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 5, 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.

10 332305B

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:

• it must be installed by a qualified electrician or serviceman.

• it must be connected to a grounded, permanent wiring system.

If an attachment plug is required in the end use application:

• it must be rated for the product electrical specifications.

• 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

NOTICE

Fuses (user supplied) are required on all DC models. 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.

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 Fuse Value

12 VDC 7.5 A

24 VDC 4 A

Graco Kit No.

571039

571040

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 connector does not exit the unit in the UP direction.

• Use a corrosion preventative electrical grease on all contacts.

332305B 11

Installation

Alarm Output and 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.

Unit in OFF Mode

Unit in ON Mode

Warning Condition

Alarm Output

Deactivated (off)

Deactivated (off)

Activated (on)

Fault Condition

Toggles On and Off once per second

Fault Condition

(Advanced Programming

Setting A7 OFF)

Fault Condition

(Advanced Programming

Setting A7 ON)

Toggles On and Off once per second

Activated (on)

Standard Remote

Illumination

(via 5 wire CPC power cable)

Off

On

Toggles On and Off once per second

Toggles On and Off once per second

Toggles On and Off once per second

Toggles On and Off once per second

Tri-Color Remote

Illumination

(via illuminated manual run input)

Off

Green

Yellow

Red

Red

Red

Alarm Relay Response

Output Tied to Common

No Faults or

Warnings

N.O.

N.C.

N.O.

Warning

N.C.

Fault

(Advanced

Programming A7

OFF)

N.O.

N.C.

Fault

(Advanced

Programming

Setting A7 ON)

N.O.

N.C.

1 second

12 332305B

Wiring and Installation Diagrams

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

Diagram Symbol Page #

Power DIN AC

14

Power DIN DC

Power CPC DC

15

16

Inputs (M12) 18

Vent Valve Outputs

Alarm Outputs

Illuminated Manual Run Input

19

20

Kits: 571030, 571031,

571032, 571033

Installation

332305B 13

F IG . 3

14

Installation

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

Pin and Related Wire Color (F IG . 3)

Pin Pin Name Color

1 Line

2 NEUTRAL

Black

White

3 Not Used Not Used

4 GROUND Green

Connector on Housing

(4)

(1) (2)

Connector on Cable

(4)

(2)

(3)

Example Wiring Diagram

(1)

3

4

1

2

332305B

Installation

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 (F IG . 4)

Pin Pin Name

3

4

1

2

-VDC

+VDC

Not Used

Not Used

Color

Black

White

Not Used

Green

Connector on Housing

(4)

(1) (2)

Connector on Cable

(4)

(2)

(3)

Example Wiring Diagram

Ignition Switch

Fuse 3

4

1

2

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

24V pump - 4A - Graco kit #571040

(1)

F IG . 4

332305B 15

Installation

Power CPC DC -15 foot: Part No. 126217

Pin and Related Wire Color (F IG . 6)

Pin Pin Name

5

6

7

3

4

1

2

Not Used

-VDC

+VDC

Not Used

Not Used

Not Used

Not Used

Color

Not Used

Black

White

Not Used

Not Used

Not Used

Green

(3)

Connector on Housing

(2)

(1)

(7)

Connector on Cable

(2)

(3)

(1)

(4)

(6)

(7)

(5)

(6)

Example Wiring Diagram

Ignition Switch

Fuse

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

24V pump - 4A - Graco kit #571040

3

4

1

2

5

6

7

(5)

(4)

F IG . 5

16 332305B

Installation

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,

571031 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 (F IG . 6)

Pin Pin Name

5

6

7

3

4

1

2

Not Used

-VDC

+VDC

LIGHT

MANUAL

Not Used

Not Used

Color

Not Used

Black

Red

White

ORANGE

Not Used

Green

(3)

Connector on Housing

(2)

(1)

(7)

(4)

Connector on Cable

(2)

(3)

(1)

(5)

(6)

(7)

(6)

Example Wiring Diagram

Fuse

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

24V pump - 4A - Graco kit #571040

L

5

6

7

1

2

3

4

(5)

(4)

F IG . 6

332305B 17

Installation

Inputs (M12)

See Technical Data, page 72 for rat-

ings.

Connector on Housing

(1)

(4)

P in out

3

4

1

2

(2)

1 S W +

2 N ot U se d

3 S W -

4 Signa l

(3)

Example Wiring Diagram

Dr y Contacts

S in k ( N P N ) 2 or 3 w ire

3

4

1

2

S ource (P N P) 2 or 3 w ire

3

4

1

2

F IG . 7

18 332305B

F IG . 8

Vent Valve Outputs

See Technical Data, page 72 for ratings.

Connector on Housing

(3)

(2)

P in out

1 N ot U se d

2 Re l ief +

3 Re l ief -

(1)

Example Wiring Diagram

1

2

3

Installation

332305B 19

Installation

Alarm Outputs

DC example shown. See Technical Data, page 72 for ratings.

Connector on Housing

(1)

P in out

(3)

(4)

1 N .O.

2 N .C.

3 COM

4 N ot U se d

(2)

Example Wiring Diagram

A l arm + 9-30V

1 Amp Max

3

4

1

2

G3

Switch c l oses on a l arm

(shown in non-a l arm position)

F IG . 9

20 332305B

Part No. 124333: Cable Pin Out (M12)

Wire Colors

Item No.

Color

1

2

3

4

Brown

White

Blue

Black

Installation

Part No. 124300: Field Wireable Pin Out

(M12)

Wire Colors

Item No.

Color

1 Brown

2

3

4

White

Blue

Black

F IG . 10

332305B

F IG . 11

21

Installation

Part No. 124594: 4 Pin Eurofast Field

Wireable Connector

Part No. 124595: 5 Pin Eurofast Field

Wireable Connector

F IG . 12 F IG . 13

22 332305B

Setup

Setup

Pressure Relief

Follow the Pressure Relief Procedure whenever you see this symbol.

Connecting to Auxiliary Fittings

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 working 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 fitting.

NOTE: When loosening pump element fitting, do NOT loosen pump element . Loosening pump element will change the output volume.

NOTICE

Do not attach unsupported equipment to auxiliary fittings 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 F IG . 14 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).

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 unintended 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 66.

• Install a pressure relief valve close to every pump outlet; before any auxiliary fitting.

F IG . 14

NOTE: A pressure relief valve can be purchased from

Graco. See Parts, page 71.

332305B 23

Setup

Setting Pump Outlet Volume

3. Tighten pump element fitting. Torque fitting to 50 in. lbs (5.6 N•m).

NOTE:

• Before making any adjustments to pump volume,

Relieve Pressure

following procedure on page 23.

• 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-clockwise to loosen. Do not remove entire pump element.

Only back pump element out enough to allow spacer to be slid on or off.

2. 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 (F IG . 15).

Do not use more than 2 spacers to adjust output volume.

No. Spacers

2

1

0

Output Volume / Minute cubic inches cubic cm

0.12

0.18

0.25

2

3

4

F IG . 15

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 (F IG . 17).

• Do not operate G3 without reservoir attached.

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.

NOTE:

• The amount of dispensed volume can vary depending on external conditions such as lubricant temperature 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 lubrication dispense.

24 332305B

Setup

Models without a follower plate:

1. Connect fill hose to inlet fitting (F IG . 16).

E

To start the pump press the manual run button.

3. Fill reservoir with grease until seal of follower plate breaches the vent hole (F IG . 18) and the majority of air is expelled from the reservoir.

D

F IG . 16 vent hole

2. For higher viscosity fluids, start pump to rotate stirring paddle during fill to prevent air pockets from forming in grease.

To start the pump press 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.

F IG . 18

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. max fill line

F IG . 17

4. Remove fill hose.

Models with a follower plate:

1. Connect fill hose to inlet fitting (F IG . 16).

2. For higher viscosity fluids, start pump to rotate stirring paddle during fill to prevent air pockets from forming in grease.

332305B 25

Setup

Filling Oil Unit

• Only use oil 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 (F IG . 19).

• Do not operate G3 without reservoir attached.

• Only use oils with viscosity at least 40 cSt.

a

F IG . 20

2. Only run pump until air is no longer dispensed with the lubricant coming out of element fitting (F IG . 21).

b

F IG . 19

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 (F IG . 20).

NOTE: When loosening pump element fitting, do NOT loosen pump element . Loosening pump element will change the output volume

F IG . 21

3. Tighten pump element fitting using two wrenches working in opposite directions (F IG . 20).

26 332305B

Quick Setup Guide

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332305B 27

Max Model Setup

Max Model Setup

Control Panel Overview (F IG . 22)

NOTE:

Programming instructions begin on page 29.

ON TIME/BACKUP TIME

• LED lights when ON

Time/Backup Time is running.

• Display shows time as MM:SS

(minutes and seconds).

i.e., 08:30 is 8 minutes: 30 seconds.

• Sets the limits for the amount of time to complete a cycle or build up pressure before a warning is activated.

• Counts down from a set time to zero.

DISPLAY

• A blinking LED under HH, MM, SS or ## identifies type of measurement unit you are setting; i.e., HH is hours.

• A blinking number on the display indicates the G3 is in SETUP

MODE.

• In RUN MODE displayed numbers count up or down. See Time ON and

Time OFF.

CYCLE / PRESSURE SETUP

• Sets either Cycle (C) or Pressure

(P) Monitoring limits for up to 3 sensors.

• Each sensor is set up and controlled independently.

MACHINE COUNT

• LED lights when Machine Count is used to control Pump OFF function.

• Counts independent machine operations with a sensor to control Pump Off duration.

• Time OFF function can be used as a backup for Machine Count.

LEFT DIRECTION ARROW /

RESET

• In ADVANCED and SETUP

MODES, moves cursor in display one field to the left.

• In RUN MODE: single press clears warning.

• In ALARM MODE: pressing and holding for 3 seconds clears fault / warning and switches cycle to OFF MODE.

F IG . 22

28

UP and DOWN ARROW

• Hold both the UP and DOWN ARROW buttons down together for 3 seconds to enter

SETUP MODE.

• In SETUP MODE, increases or decreases number values shown in display.

OFF TIME/BACKUP TIME

• LED lights when OFF

Time/Backup Time is used to control Pump OFF function.

• Value is entered in HH:M.

• Displays in HH:MM (hours and minutes) when > 1 hour.

• Times pump rest between cycles.

• Counts down from set time to zero.

• Can be set up to use as a backup for Machine Count control.

ALARM ICONS

LED next to icon lights when a fault / warning event occurs

during a run cycle. See page 57

for a complete description of these alarm scenarios.

PIN ICON

• LED next to icon lights indicating PIN is required to enter setup.

• In SETUP MODE LED lights when setting up the

PIN.

PRELUBE

LED next to icon lights indicating LED lights when Prelube function is enabled.

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 manual run cycle.

332305B

Max Model Setup

Programming the Max Model

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 button located on the control panel (example shown on the right) for 1 second to move to the OFF mode.

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 the following section: Entering a

PIN Code to Access

Setup Mode.

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 programming settings and therefore, an option for adding PIN Code authorization is available.

The instructions for setting up PIN Code Authorization are provided in the Advanced Programming section of this manual. See page 46.

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 run 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 number. 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 display will not blink.

332305B 29

Max Model Setup

Setting the Real Time Clock

DMS ™ Equipped Models Only

NOTE: Set the real time clock prior to plugging the USB flash drive into the pump.

Enter the Year:

• The year displays.

The first programmable character, the decade, blinks indicating the device is ready to program the decade digit of the year.

• The LED under the # sign lights while setting the year.

1. Use the UP and DOWN arrow buttons to move up and down through the number 0-9 until the number for the current decade is displayed in the field.

2. Press the ENTER button to set the decade number. The cursor automatically moves to the next field, the year number.

3. Use the UP and DOWN arrow buttons to move up and down through the number 0-9 until the number for the current year is displayed in the field.

4. Press the ENTER button to set the year number.

The 3-character month displays indicating the G3 is now ready to program the month.

Enter the Month:

1. Set the 3 character month by using the UP and DOWN ARROW buttons to move up and down through

30 the list of months until the current month is displayed in the field.

2. Press the ENTER button to set the month.

The 2-digit date displays indicating the G3 is now ready to program the date.

Enter the 2-digit Date:

The first programmable character of the 2-digit date blinks indicating the device is ready to program the first digit of the date.

The LED under the # sign lights while setting the date.

1. Use the UP and DOWN ARROW buttons to move up and down through the numbers 0-3 until the first digit of the date is displayed in the field.

2. Press the ENTER button to accept the selection. The cursor automatically moves to the second digit of the date.

3. Use the UP and DOWN ARROW buttons to move up and down through the numbers 0-9 until the second digit of the date is displayed in the field.

4. Press the ENTER button to set the date.

The time displays indicating the G3 is now ready to program the time.

Enter the Time:

• The time displays in 24-Hour format. i.e., 2:45 PM displays as 14:45.

• The clock is set in Hours and Minutes (HH:MM).

• The LED under the

HH lights when setting hours and the

LED under the MM lights when setting minutes.

or

332305B

Max Model Setup

• The first programmable number of the HH (hour) filed blinks, indicating the device is ready to program the first digit of the hour.

• When programming a time of less then 12 hours, you must program a leading zero in the first number field and press the ENTER button to save the zero.

1. Use the UP and DOWN ARROW buttons to move up and down through the numbers 0-2 until the desired number appears in the first hour (HH) field.

2. Press the ENTER button to set the number.

3. Use the UP and DOWN ARROW buttons to move up and down through the numbers 0-9 until the desired number for the second HH number field appears.

4. Press the ENTER button to set the number.

5. The next number field to the right blinks and the

LED under the MM lights indicating the G3 is ready to program the minutes fields.

6. Repeat steps 1-4 to set the minutes (MM) fields.

7. After pressing the ENTER button to set the time, the programmed Time information is saved.

Programming ON Duration

• OFF, C1 (C2, C3) or

P1 (P2, P3) displays, identifying the function you are programming.

• Selection of OFF, C1 (C2, C3) or P1 (P2, P3) designates the way pump run time is controlled:

• C1, C2, C3 - Completing a specific number of cycles measured by an external prox/cycle switch

• P1, P2, P3 - Reaching a specific pressure threshold measured by an external pressure switch - OR ,

• OFF - A specific duration of time elapses.

• The LED next to C/P1 lights, indicating which sensor of the pump control you are programming using either a specific number of cycles or by monitoring a pressure switch.

• C / P2 and C / P3 controls functions to the second and third sensors (when sensors are used).

• Only sensor inputs that are available on the unit can be programmed.

NOTE: Field cannot be left blank. If C / P2 and C /

P3 are not used, OFF must be entered instead.

Cycle (C1, C2, C3) Setup

Cycle controls the number of lube cycles (as monitored by an external cycle monitor) completed before the pump rests.

NOTE:

• You must program at least one cycle. Zero is not an available option.

1. Use UP or DOWN arrow button to toggle display between

OFF / C1 / P1 on the display.

2. When C1 is on display, press the

ENTER button to save selection and begin programming Cycle data.

• The first number displayed after the

“C1” on the display blinks, indicating the device is ready to program the number of C1 cycles.

• The LED under the

# sign lights when setting the number of cycles.

3. Program the number of cycles by pressing the UP or

DOWN ARROW button to move up or down through number 0-9.

332305B 31

Max Model Setup

4. The cycle field is a 2 digit number.

When the correct first numeral of the number displays, press the ENTER button to save the number. The cursor automatically moves to the second number field.

NOTE: A leading zero (0) must be entered in the first field if the number of cycles is fewer than 10.

5. Press the ENTER button, to save the C1 information.

• If your G3 is equipped with more than one sensor input, you will automatically be prompted to begin selecting the pump control type for the next sensor. Repeat steps 1 - 5 to program cycles for C2 and C3.

NOTE: If C / P2 and C / P3 are not used, the default

OFF setting must be entered instead.

6. After you set the last field and press the

ENTER button, the G3 saves the Cycle information and moves to setting

Backup Time, page 34.

Pressure Control (P1, P2, P3) Setup

• For injector systems, monitoring pressure can be used as a way to ensure sufficient pressure has been reached to activate injectors. The pump runs, building up enough pressure to cause injectors to dispense fluid. Pressure continues to build to a preset maximum, activating the (user supplier) pressure switch. Then an external (user supplied) vent valve opens and pressure reduces, priming the injector for the next cycle.

• Pressure control is an ON / OFF selection only.

1. Use the UP or DOWN arrow button to toggle between OFF

/ C1/ P1.

2. When P1 displays, press

ENTER button to save selection.

3. If your G3 comes equipped with more than one sensor input, you will automatically be prompted to begin selecting pump control type for the next sensor. Repeat steps 1 - 2 to program P2 and P3.

If P1 / P2 / P3 is selected the vent valve time is automatically set to 5 minutes. If the unit is used in an injector based system and a sensor input is not used, the user must update the vent valve time in advanced programming. (See Advanced Programming, A-3 Vent Valve Time, page 47.)

Input Not Used

Select OFF if your system does not use the applicable input.

1. Use UP or DOWN arrow button to toggle between OFF /

C1 / P1 on the display.

2. When

OFF is on the display, press the

ENTER button to save selection.

If the sensor inputs are available and none are used in the ON Mode, the definition of the entered time is ON

TIME.

Examples:

Model G3-G-24MX-2LFL00-1DMVA2R3 has 4 sensors, so C/P1, C/P2, and C/P3 and Machine Count can all be programmed.

Model G3-G-24MX-2LFL00-10CV00R0 has 1 sensor, only C/P1 is available for programming.

Backup Time

In both Cycle and Pressure Modes, a maximum run

Time (Backup Time) for the lubrication period must be set up. If this Time expires before the lubrication is completed an alarm/warning is triggered and the pump stops.

32 332305B

Max Model Setup

To determine the Backup Time, Graco recommends the user verify the length of time it takes to complete a typical cycle and double that value (to a maximum of 30 minutes).

Backup Time is setup after Cycle or Pressure Sensor

Setup is complete.

NOTE:

• The LED next to the clock in the ON field lights, indicating the Backup Time is being programmed.

• BACKUP (ON) Time is set as minutes and seconds

(MM:SS) only.

• The small flashing LED under the MM indicates you are setting minutes.

• The first field (left side of display) blinks indicating the device is ready for you to begin programming.

Programming Backup Time

NOTE: When programming a time of less than 10 minutes you must program the leading zero in the first number 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 (minutes) 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.

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).

• An LED flashes under either MM when programming minutes

OR SS when programming seconds.

OR

• In SETUP MODE, the number displayed in the first field, on the left side of display blinks, indicating the device is ready to program 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 minutes 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 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 (minutes) field.

332305B 33

Max Model Setup

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.

PUMP OFF / REST Setup

After setting the parameters for either Cycle (C1, C2 or

C3) or Pressure (P1, P2, or P3) ON modes, the OFF or pump rest cycle must be set up. There are 3 ways to control this function:

• Machine Count switch activation, or

• Machine Count activations limited by a maximum Time, or

• A specific set amount of Time (similar to Time

Mode).

• If the machine count sensor input is available and not used in the OFF Mode, the definition of the entered time is OFF TIME.

Machine Count

1. After you set the last ON Time field and press the ENTER button, the G3 automatically switches to the

Machine Count setup.

Notice the LED next to 123 on the G3 display lights indicating you are now in the Machine Count setup mode.

2. Press the UP or DOWN

ARROW button to move up or down through number 0-9.

3. When the correct number displays, press the ENTER button to set the number.

NOTE: If the machine count input is available on the unit and not used, the value MUST be set to zero (0).

4. Repeat 2 - 3 to set the remaining fields.

NOTE: After the Machine Count value is entered, the

G3 can be programmed to backup the machine count input with time.

Backup Time Setup

1. The OFF Time LED lights.

OFF displays.

2. Press the UP or DOWN

ARROW button to change

OFF to ON on the display.

3. Press the ENTER button to set the selection.

Backup Time

• The LED next to the clock in the OFF field lights, indicating you are setting the Backup Time parameters.

• OFF Time is set in Hours and Minutes

(HH: MM).

34 332305B

Max Model Setup

• An LED flashes under either HH when programming hours OR

MM when programming minutes.

OR

• In SETUP MODE the number displayed in the first field, on the left side of display blinks, indicating the device is ready to program the Backup Time hours.

• The total amount of Backup Time must be at least twice as long as the programmed 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 Backup Time

NOTE: When programming a Backup 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 Backup 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.

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 information is saved.

7. After selecting ON, refer to page 32.

NOTE: Backup time can be set in HH:MM for the machine count input.

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 programming hours OR

MM when programming minutes.

• In SETUP MODE the number displayed in the first field, on the left side of display blinks, indicating the device is ready to program the OFF Time hours.

OR

• The total amount of OFF Time must be at least twice as long as the programmed 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.

332305B 35

Max Model Setup

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.

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 information 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 Delay setup.

Notice the LED next to the prelube icon on the G3 display lights indicating you are now in the Prelube setup mode.

2. OFF displays. If you want the prelube cycle to begin immediately, 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 prelube 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 seconds). 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

36 332305B

Max Model Setup 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.

DMS

Models Only

Downloading Data

1. Plug the USB flash drive into the USB port.

NOTE: The G3 pump stops pumping as soon as the

USB flash drive is plugged into it.

2. The system automatically begins downloading data to the USB drive.

3. “data” is displayed while the system is downloading files.

4. When download is finished, “done” is displayed.

5. G3 pump restarts cycle in the OFF mode.

6. Remove the USB flash drive.

Storing Pump Program Settings to the Flash Drive

The pump program settings file is named:

GRACO/G3Config/g3config.bin. This file cannot be modified. Modification of the file or file name may cause it to be unusable.

1. Plug the USB flash drive into the USB port.

NOTE: The G3 pump stops pumping as soon as the

USB flash drive is plugged into it.

2. The system automatically begins downloading data to the USB drive.

3. “data” is displayed while the system is downloading files.

4. When download is finished, “done” is displayed.

5. G3 pump restarts cycle in the OFF mode.

6. After the download is complete, press and hold the UP and DOWN ARROW button for 3 seconds to store the current setup to the USB flash drive.

7. “data” is displayed while the unit is downloading and storing the configuration on the USB drive.

8. When configuration is stored, “done” is displayed.

9. G3 pump restarts cycle in the OFF mode.

10. Remove the USB flash drive.

Uploading Pump Program

Settings to the Pump

1. Plug the USB flash drive into the USB port.

NOTE:

• The USB flash drive must contain file

GRACO/G3Config/g3config.bin.

• The G3 pump stops pumping as soon as the

USB flash drive is plugged into it.

2. The system automatically begins downloading data to the USB drive.

3. “data” is displayed while the system is downloading files.

4. When download is finished, “done” is displayed.

5. G3 pump restarts cycle in the OFF mode.

6. After the download is complete, press and hold the

RESET button and UP

ARROW button for 3 seconds to upload the setup stored in the USB flash drive.

7. “data” is displayed while the unit is uploading the configuration data.

8. When upload is finished, “done” is displayed.

332305B 37

Max Model Setup

9. G3 pump restarts cycle in the OFF mode.

10. Remove the USB flash drive.

11. After the USB flash drive is removed, press and hold the

UP and DOWN ARROW buttons for 3 seconds to enter the SETUP MODE (see

Entering Setup Mode, page 29).

12. In SETUP MODE, set the YEAR, MONTH, DATE and TIME (see Setting the Real Time Clock, page

30).

13. After pressing the ENTER button to set the TIME, press the RESET button to exit the SETUP MODE.

Viewing the UNIT DMS ID Number

1. In RUN mode, press and hold the

DOWN ARROW button.

2. The Unit DMS ID number displays. The unit continues to normal operation while the DMS ID is displayed.

3. Release the DOWN ARROW button after viewing the DMS ID number.

38 332305B

Operation / Data Log

Operation / Data Log

During operation the G3 Pump stores information as

Log and Summary Files.

Logs contain the following information:

• Log Name

• DMS ID Number

• Current Software Graco Part Number

• Current Software Version

• Date and Time of Upload

System Event Log

The System Event Log lists the date and time of the last

800 common system events such as pump cycles, manual run and setting changes. The most recent event is listed first.

The log file is stored in a folder structure created by the pump DMS ID and download date. If multiple downloads are done on the same date, the existing files will be written over.

The folder structure is as follows:

GRACO/G3_{DMS_id}/{download date - YYYYmmDD}/EVENTLOG.CSV

Example: GRACO/G3_00025/20100911/EVENT-

LOG.CSV.

Sample System Event Log

Example Event Log 1 : Pump cycle of a divider valve system with a proximity switch set to detect 5 divider valve cycles.

G3 System Event Log

DMS ID Number: 0025 (see page 38)

Software Part Number: 16F821

Software Version: 1019

09/29/2010 14:1400

Date Time Description

9/29/2010 14:13:02 Pump Run Off

9/29/2010 14:13:02 C1 Cycle Completed

9/29/2010 14:12:39 C1 Cycle Detected

9/29/2010 14:12:34 C1 Cycle Detected

9/29/2010 14:12:28 C1 Cycle Detected

9/29/2010 14:12:23 C1 Cycle Detected

9/29/2010 14:12:17 Pump Run On

332305B 39

Operation / Data Log

Example Event Log 2 : Pump cycle of an injector valve system with a pressure switch feedback.

Date Time Description

9/29/2010 13:28:12 Venting Completed

9/29/2010 13:23:12 Venting Detected

9/29/2010 13:23:11 Pump Run Off

9/29/2010 13:23:11 P1 Pressure Completed

9/29/2010 13:22:20 Pump Run On

Venting Detected In an injector system, the pump on cycle has completed and the system is currently venting pressure through the vent valve.

Prelube Initiated The pump has entered a prelube delay after powering up.

Prelube Completed The pump has completed prelube delay and will begin a pump on cycle.

Successful Pin

Code Entry

The pin code was successfully entered and the user has entered setup mode.

Common System Events are listed below.

Pump Run On

Pump Run Off

The pump entered an on cycle and is operating and dispensing material.

The pump entered an off cycle and is not dispensing.

Pump Run Cancelled

G3 Power On

A pump on cycle was cancelled by pressing the cancel button on the front panel and holding it for 3 seconds.

The pump powered on.

G3 Power Off

Program Variable

Change

The pump powered off.

The setup mode was entered.

C1 Cycle Detected The system is set up to monitor a prox-

C2 Cycle Detected

C3 Cycle Detected imity switch on a divider valve using the sensor input (C1, C2, and/or C3) and has detected one divider valve cycle.

C1 Cycle Completed

C2 Cycle Completed

The system is set up to monitor a proximity switch on a divider valve using the sensor input (C1, C2, and/or C3) and has achieved the number of counts required by the system for that input, completing a pump on cycle.

C3 Cycle Completed

P1 Pressure Completed

P2 Pressure Completed

P3 Pressure Completed

The system is set up to monitor a pressure switch for an injector system using sensor input (P1, P2, and/or P3), the system has achieved pressure and the switch has activated, completing a pump on cycle.

Machine Count

Completed

The system is set up to monitor a sensor on the equipment being lubricated using the machine count input and has achieved the number of counts required by the system for that input, completing a pump off cycle and initiating a pump on cycle.

Local Manual Run

Initiated

Remote Manual

Run Initiated

The manual run button was pressed, initiating a pump on cycle.

The remote manual run button was pressed initiating a pump on cycle.

Error Log

The Error Log lists Set Time and Clear Time for the last

400 faults and warnings. The most recent event is listed first.

The log file is stored as:

GRACO/G3_{DMS_id}/{download date - YYYYmmDD}/ERRORLOG.CSV

Example: GRACO/G3_00025/20100911/ERROR-

LOG.CSV.

Sample Error Log

G3 Error Log

DMS ID Number: 00025 (see page 38)

Software Part Number:16F821

Software Version:0205

12/31/2015 23:04:00

Date Time Description

12/31/2015 23:03:54 Low Level Cleared

12/31/2015 23:03:42 Low Level Fault

12/31/2015 23:03:32 Low Level Warning

12/31/2015 23:03:22 P2 Not Detected Cleared

12/31/2015 23:03:22 C1 Not Detected Cleared

12/31/2015 23:03:19 P2 Not Detected

12/31/2015 23:03:19 C1 Not Detected

12/31/2015 23:02:20 Machine Count Not Detected

12/31/2015 23:02:11 Machine Count Not Detected

40 332305B

Operation / Data Log

Common Error Log entries are listed below.

Software Fault

Low Level Warning

An internal software error occurred. Contact Graco Customer Service.

The unit entered a low level warning mode and is running low on material. The pump continues to dispense material for the duration of the low level alarm time specified by the unit.

Low Level Fault The alarm time in low level warning has elapsed. The unit will not pump until the reservoir is filled and the fault is cleared.

Cycle 1 Not Detected In a divider valve system, the

Cycle 2 Not Detected system has not received the programmed number of divider

Cycle 3 Not Detected valve cycles for the specified input in the programmed backup time.

Pressure 1 Not

Detected

Pressure 2 Not

Detected

Pressure 3 Not

Detected

System Already Pressurized 1

System Already Pressurized 2

System Already Pressurized 3

Machine Count Sensor

Failure

In an injector system the system has not received a signal from the pressure switch in the designated backup time.

In an injector system the pressure switch is activated when the unit enters a pump on mode and may not have vented properly.

Motor Overcurrent

The specified number of machine count input activations was not received within the designated backup time.

The unit is out of expected motor current range. Check the system to determine that it is functioning correctly (i.e., no blocked lines). Continued operation at excessive motor currents will cause degradation in pump life.

High Temperature

Warning

Low Temperature

Warning

Internal temperature of the unit is above the designated operating. Check the unit and system to determine that it is functioning correctly. Operating outside of the specified temperature range may cause reduced performance and possible unit failure.

Internal temperature of the unit is below the designated operating. Check the unit and system to determine that it is functioning correctly. Operating outside of the specified temperature may cause reduced performance and possible unit failure.

USB Unable to Mount The USB flash drive that was installed was unable to connect and communicate with the pump.

USB Unsupported

Device

The USB flash drive is unsupported. Use a different flash drive.

USB File Not Found

USB Folder Navigation The pump program setting file was not found or created correctly. Restore the setting file to the flash drive.

USB Invalid File

The pump program setting file was not found or created correctly. Restore the setting file to the flash drive.

The pump program settings file was not found or created correctly. Restore the setting file to the flash drive.

Failed Pin Code Entry A failed attempt was made to enter the pin code password.

332305B 41

Operation / Data Log

Functional Summary

The Functional Summary contains two types of data.

• The first report type, labeled User under the Type heading in the first column of the Sample Functional

Summary, only provides data compiled since the last time the Functional Summary was reset through present day (see A6 - Clearing the Functional and

Technical User Summary, page 49).

This is very similar to the resettable trip odometer in your car.

• The second report type, labeled Factory under the

Type heading in the first column of the Sample

Functional Summary, covers the cumulative life of the pump from the first day it was put into service through present day.

This is very similar to an odometer in your car.

The log file is stored as:

GRACO/G3_{DMS_id}/{download date - YYYYmmDD}/FUNCSUM.CSV

Example: GRACO/G3_00025/20100911/FUNC-

SUM.CSV

Sample Functional Summary

(see page 38)

42 332305B

Common Functional Summary Data entries are listed below.

Number of Cycles The number of lubrication cycles the unit has started.

Total Run Hours

Total Powered On Hours Total number of hours that the unit has been powered on.

Local Manual Run The number of times the manual run button was pressed.

Remote Manual Run

Total amount of hours the pump has been in the ON mode of the

ON/OFF cycle.

Average Run Time

The number of times the remote manual run button was pressed.

The average amount of time per lubrication cycle that the pump has been running (MM:SS).

Average Cycle 1 Time

Average Cycle 2 Time

Average Cycle 3 Time

Average Duty Cycle

Max Duty Cycle

The average amount of time the unit has been operating before the specified feedback for the sensor input was received (proximity switch counts in divider valve systems and pressure switch activation in injector systems).

The average percentage of time the unit has been pumping while it has been powered on.

The highest percentage of time for one lubrication cycle that the unit has been pumping while it has been powered on.

Total number of low level faults.

Total Low Level Faults

Total Cycle Pressure

Faults

Total Other Faults

Total Fault Hours

Total number of faults related to sensor feedback in an injector or divider valve system.

Faults other than low level or sensor feedback.

Number of hours the system has been powered on in fault mode.

Total Low Level Warnings Number of low level warning conditions.

Total Cycle Pressure

Warnings

Total number of warning conditions related to sensor feedback.

This is only applicable if fault retries are used.

Total Other Warnings All other warnings including temperature and motor current.

332305B

Operation / Data Log

43

Operation / Data Log

Technical Summary

The Technical Summary contains two types of data.

• The first report only provides data compiled since the Pump Summary was reset to present day (see

A6 - Clearing the Functional and Technical User

Summary).

This is very similar to the resettable trip odometer in your car.

• The second is a report that covers the cumulative life of the pump from the first day it was put into service to present day.

This is very similar to an odometer in your car.

The log file is stored as:

GRACO/G3_{DMS_id}/{download date - YYYYmmDD}/TECHSUM.CSV

Sample Technical Summary

G3 Technical Summary

DMS ID Number: 00025 (see page 38)

Software Part Number:16F821

Software Version: 0205

12/27/2010 9:50:51

Latest Values

Temp Voltage

31C 23.877

Example: GRACO/G3_00025/20100911/TECH-

SUM.CSV

Common Technical Summary Data entries are listed below.

Average Input Board

Voltage (DC)

Peak Input Board Voltage (DC)

The average input voltage measured by the internal circuit board.

The peak input voltage measured by the internal circuit board.

Average Motor Current The average motor current measured by the unit.

Peak Motor Current The peak motor current measured by the unit.

Average Internal Temperature

Peak Internal Temperature

Low Internal Temperature

The average internal temperature seen by the unit.

The peak internal temperature seen by the unit.

The lowest internal temperature seen by the unit.

Type

User

Factory

Start Date Average

Board

Peak

Board

Average

Motor

Peak

Motor

Average

Internal

12/21/2010

Voltage

23.877

Voltage

23.877

Current

0.062

Current Temp

0.06230C

9/30/2010 22.804

23.877

1.091

0.36233C

Peak

Internal

Temp

35C

42C

Low

Internal

Temp

28C

-10C

44 332305B

Advanced Programming

Advanced Programming

There are 7 Advanced Programming options. The following Table Identifies each option and when it is used.

Advanced

Option

A1

A2

A3

A4

A5

A6

A7

Model Setting Format/ Description Why Use This?

Max Lockout

Code

(Optional)

Secures setup modes with

PIN

Level

Alarm Time

(minutes:seconds) sets amount of time between Low Level Warning to Low Level Fault.

Default = 3 minutes

Time

Valve (minutes:seconds) sets amount of time vent valve stays open after Pump

ON Mode.

Prevents unauthorized users to adjusting settings.

To accommodate most lubrication situations, a conservative 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.

• In an injector based system that does not use a sensor for feedback, determines the amount of time the system vents.

• Vent time can be modified.

Max

Default = 5 minutes

Alarm Retry Sets number of automatic retries after a Cycle or Pressure Alarm.

Establishes the number of times the unit automatically retries lubricating after a cycle or pressure alarm to determine if a temporary or false signal can be cleared.

Max Active

Alarm

Default = 0

Changes alarm output behavior.

Uses alarm output to determine if a unit has an alarm AND/OR loses power.

Default = OFF The output turns ON when power is applied. It turns OFF when power is lost or an alarm occurs.

Normal operation (OFF) will only activate alarm output in an alarm condition when power is on.

DMS ™

Models

Equipped

Functional and Technical User

Summary

Reset

Clears the Functional and

Technical User Summaries

Max Constant Changes alarm output

Alarm Output on Fault behavior.

Default = OFF

Can change (set to ON) to activate alarm with power ON and deactivate with power

OFF OR warning.

Used to manage power outage.

Allows user to track lube events from a specific point (reset), i.e. a month to month evaluation.

This function changes the behavior of the alarm output in a fault from either toggling once every second or steady on.

332305B 45

Advanced Programming

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 unauthorized 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.

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 number. 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.

Selecting Advanced Setup Options

1. Press the UP or DOWN

ARROW button to move up or down through Advanced

Options A1 - A7.

2. Press the ENTER button to set the selection.

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 seconds.

If the G3 was previously set up to require a

PIN Code, the LED next to the LOCK ICON lights, indicating a PIN Code is required.

46 332305B

Advanced Programming

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 Warning and a Low Level Fault to help protect unit from running dry.

The maximum recommended length of time is 3:00 minutes.

Fault, and Low Level LED illuminate. ( Max Model Display shown in illustration below ).

F IG . 23

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.

A3 - Vent Valve Time

The Vent Valve Time is the amount of time the vent valve stays open after a cycle is completed.

The recommended Vent Valve Time is 5 minutes.

To bypass the Vent Valve Time enter a value of 00:00.

Vent Valve time must be less than the programmed OFF

time (page 35). If it is not set to a value less than the

programmed OFF time, the G3 will automatically adjust the time to a value 2 seconds less than the set OFF time.

NOTE: When programming a time of less than 10 minutes 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 time use the UP or

DOWN ARROW button to scroll through numerals 0 to 9 until the desired number appears in the first MM (minutes) 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.

332305B 47

Advanced Programming

To set Vent Valve Time:

NOTE:

• The LED next to the clock in the OFF field lights and P1, P2, and P3, indicating the Vent Valve Time is being programmed.

7. After pressing the ENTER button to set the last seconds field, all the programmed Time information is saved.

Unit exits Advanced Programming.

• Time is set as minutes and seconds (MM:SS) only.

• The small flashing

LED under the MM indicates you are setting Minutes.

• The first field (left side of display) blinks indicating the device is ready for you to begin programming.

• When programming a time of less then 10 minutes 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 Time use the UP or DOWN ARROW button to scroll through numerals 0 to 5 until the desired number appears in the first minute field.

2. Press the ENTER button to lock in the selection. The next minute 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 minute field.

4. Press the ENTER button to lock in the selection.

5. The next number field to the right flashes and the LED lights under SS; indicating it is ready to program the Seconds fields.

6. Repeat steps 1 - 4 to set the MM (seconds) fields.

A-4 Alarm Retry

Programs the number of times G3 will automatically retry running a lubrication cycle after a cycle or pressure alarm activates. The default setting is 0. For assistance determining a reasonable number of Alarm Retries to program for your application, contact Graco Customer

Service or your local Graco distributor.

1, 2, and 3 and Fault LED’s illuminate.

F IG . 24

To set the Alarm Retry:

1. The default value

0000 appears in the display.

2. Press the UP or DOWN

ARROW button to move up or down through number 0-9.

48 332305B

3. When the correct number displays, press the ENTER button to set the number.

4. Repeat 2 - 3 to set the remaining fields.

5. Press the ENTER button to exit

Advanced Programming.

A-5 Active Alarm

Changes the alarm output behavior. Uses output to determine if a fault has occurred.

Fault and ON LED’s illuminate.

Advanced Programming

3. Press the ENTER button to exit

Advanced Programming.

A6 - Clearing the Functional and Technical

User Summary (DMS

Models only)

The Pump Summary shows run details since the last time the summary was cleared.

F IG . 25

1. The default OFF displays.

2. Press the UP or DOWN

ARROW button to change

OFF to ON on the display to activate alarm condition.

332305B

F IG . 26

1. Press the UP or DOWN

ARROW button to move through Advanced Options until Advanced Option A6 is displayed.

2. Press the ENTER button.

3. “Data” displays.

4. Press the RESET button. “Reset” displays.

The summary data is cleared.

5. Press the RESET or

ENTER button to exit.

49

Advanced Programming

A-7- Constant Alarm Output on Fault

This function changes the behavior of the alarm output in a fault from either toggling once every second

(default) or steady on.

Fault and Warning LEDs Illuminate

HH MM SS ##

!

ON

MM : SS

OFF

HH : MM

C

P

1

C

P

2

C

C

P

3 P

1 2 3

F IG . 27

1. The default OFF is displayed. The alarm output will toggle once a second.

2. Press the UP or DOWN

ARROW to change OFF to

ON on the display to change the alarm output to be on steady

3. Press the ENTER button to exit

Advanced Programming.

50 332305B

Run Mode

Run Mode

Time Control

After setup is complete, the G3 automatically begins to run the OFF Time sequence (F IG . 28).

• 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 F IG . 28 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 (F IG . 29).

(Notice the ON Time LED is now illuminated on the display.)

• The example shown in F IG . 29 shows an ON Time of 8 minutes and 42 seconds before the lubrication cycle ends.

HH MM SS ##

!

ON

MM : SS

OFF

HH : MM

HH MM SS ##

!

ON

MM : SS

OFF

HH : MM

C

P

1

C

P

2

C

C

P

3 P

1 2 3

C

P

1

C

P

2

C

C

P

3 P

1 2 3

F IG . 28

F IG . 29

• 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 illuminated (F IG . 28).

This sequence repeats itself until the device is reprogrammed or an alarm occurs.

• If power to the pump is lost during a lubrication cycle, when power is restored the pump will resume the cycle with the same amount of time remaining in the cycle as when the power was lost.

332305B 51

Run Mode

Lubrication Mode (Pump ON) Controls

In Max models the Lubrication Mode (Pump ON) can be controlled by either cycle and/or pressure sensors.

If cycle and/or pressure controls have been set to something other than OFF the display will alternate between cycles (C1, C2, C3) and/or active sensors (P1, P2, P3) and Backup Time.

If cycle or pressure controls have been set to OFF then the Lubrication Mode (Pump ON) will be controlled by

On Time (see Time Control, page 51).

With cycle and/or pressure controls set, the lubrication cycle (Pump ON) is ended by meeting all required cycle and/or pressure settings.

Cycle Control

• A set number of triggered counts in a cycle based system (C1). Typically a proximity switch connected to a divider valve.

• The LED next to the appropriate sensor (C/P1,

C/P2, C/P3) illuminates.

• The display indicates the sensor (C1, C2, C3) and the remaining cycles for that sensor (F IG .

30).

The example shown in F IG . 30 shows sensor C1 with 5 cycles remaining.

Pressure Control

• A single triggered count in a pressure based system (P1). Typically a pressure switch on the end of a line of injectors.

• The LED next to the appropriate sensor (C/P1,

C/P2, C/P3) illuminates (F IG . 31 and F IG . 32).

• The display indicates the sensor (P1, P2, P3) and whether the pressure switch for that sensor has been triggered or not.

- 01 = pressure switch has not been triggered

- 00 = pressure switch is triggered.

The example shown in F IG . 31 shows sensor P1 with a pressure switch that has been triggered.

F IG . 32 (page 53) shows sensor P2 with a pressure switch that has NOT been triggered.

HH

ON

MM SS

MM : SS

##

OFF

HH : MM

!

HH MM SS ##

!

C

P

1

C

P

2

C

C

P

3 P

1 2 3

ON

MM : SS

OFF

HH : MM

F IG . 31

C

P

1

C

P

2

C

C

P

3 P

1 2 3

F IG . 30

52 332305B

F IG . 32

332305B

HH MM SS ##

!

ON

MM : SS

OFF

HH : MM

C

P

1

C

P

2

C

C

P

3 P

1 2 3

Run Mode

Backup Time

• In both Cycle and Pressure modes a Backup

Time (maximum run time) has been set.

• The LED(s) next to all programmed sensors

(C/P1, C/P2, C/P3) illuminate.

• The display shows time remaining until a fault.

The example shown in F IG . 33 shows 14 min-

utes and 33 seconds left until the fault occurs.

• If all cycle and/or pressure requirements are met the unit exits the lubrication cycle (Pump

ON) and enter the rest cycle (Pump OFF).

HH MM SS ##

!

ON

MM : SS

OFF

HH : MM

C

P

1

C

P

2

C

C

P

3 P

1 2 3

F IG . 33

Rest Mode (Pump OFF) Controls

In Max models the Rest Mode (Pump OFF) is controlled by machine counts.

If the Machine Count is set to a value greater than 0000 and the Backup Time option is activated, the display will alternate between Machine Counts and Backup

Time.

If Machine Count has been set to a value greater than

0000 and the Backup Time option is NOT activated , the display will only show the number of Machines Counts remaining.

53

Run Mode

With machine count set, the Rest Cycle (Pump OFF) is ended when the machine count reaches zero (0000).

Machine Count

• A set number of triggered counts.

• The LED next to 1-2-3 illuminates (F IG . 34).

• The display indicates the number of machine counts remaining.

The example shown in F IG . 34 shows the remaining number of machine counts is 0045.

Backup Time

In Machine Count mode, if a Backup Time (maximum rest time) has been set:

• The LED next to 1-2-3 illuminates (F IG . 35).

• The display shows the amount of time remaining till a fault.

The example shown in F IG . 35 shows 4 hours and 17 minutes remaining until a fault occurs.

• If the Machine Count requirements are met the unit will exit the Rest Mode (Pump OFF) and enter the Lubrication Mode (Pump ON).

HH MM SS ##

!

HH MM SS ##

!

ON

MM : SS

OFF

HH : MM

ON

MM : SS

OFF

HH : MM

C

P

1

C

P

2

C

C

P

3 P

1 2 3

C

P

1

C

P

2

C

P

3

C

P

1

2 3

F IG . 34 F IG . 35

OFF Time

In Max models if the Machine Count is set to 0000 then

Reset Mode (Pump OFF) is controlled with OFF Time

(see Time Control, page 51).

54 332305B

Run Mode

Additional Controls

Venting

In Max models a Vent Time can be set using the

Advanced Programming mode (page 47). This is typically done in a Pressure Based System (P1) to allow injectors to reset.

• Unit vents for a set amount of time (not displayed).

• The LED’s next to C/P1, C/P2, C/P3 flash while unit is venting.

• If Machine Count is set, the display will alternate between machine counts remaining and backup

time (Max Model Rest Mode, page 53).

• If Machine Count has been set the LED next to

1-2-3 illuminates (F IG . 34, page 54).

• If Machine Count has not been set the display

shows OFF Time (See Time Control, page 51).

• If Machine Count has not been set the LED next to the clock in the OFF field illuminates (See

Time Control, page 51).

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.

• Max Model - display shows Cycle/Pressure/Backup Time (See Max Model Lubrication

Mode Controls, page 52).

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 illuminated (F IG . 36).

• The Prelube LED lights (F IG . 36).

• The display shows time remaining until lubrication cycle begins. The example shown in F IG . 36 shows 8 minutes and 14 seconds left until a lubrication cycle begins.

HH MM SS ##

!

ON

MM : SS

OFF

HH : MM

C

P

1

C

P

2

C

P

3

C

P

1

2 3

F IG . 36

332305B 55

Run Mode

Manual Run Cycle

To run an extra (non-programmed) lubrication cycle, push the Manual Start button.

NOTE: Manual Run option is not available while unit is in Vent Mode.

56 332305B

Alarms

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

Low Level

Warning

What it Looks Like

HH MM SS ##

ON

MM : SS

OFF

HH : MM

!

What it Indicates

Level of lubricant in reservoir is low and additional lubricant needs to be added.

Unit continues to operate as normal for a limited period of time until a low level alarm is triggered.

Solution

Add lubricant to reservoir.

After lubricant is added, press the

RESET button to clear the warning.

C

1

P

C

P

2

C

C

P

3 P

1 2 3

332305B 57

Alarms

Low Level

Fault

HH MM SS ##

!

ON

MM : SS

OFF

HH : MM

C

P

1

C

P

2

C

C

P

3 P

1 2 3

Cycle /

Pressure

Warning

HH MM SS ##

!

ON

MM : SS

OFF

HH : MM

C

P

1

C

P

2

C

C

P

3 P

1 2 3

Level of lubricant in reservoir is low and additional lubricant needs to be added.

Unit stops pumping and displays amount of accumulated time since the alarm was triggered.

Add lubricant to reservoir.

After lubricant 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 47.

System fails to relieve pressure or a lubrication cycle was not completed in the user-defined amount of time.

Examine system to determine if you have a plugged or broken line or other component failure, i.e., divider valve, injector.

Unit will continue to operate for the number of lubrication cycles set by the warning retry parameter

(see Advanced Program-

ming, page 45).

Press the

RESET button to clear warning.

If the warning condition clears itself on the next automatic lubrication cycle, the warning is cleared and the unit continues normal operation.

58 332305B

Cycle /

Pressure

Fault

HH MM SS ##

!

ON

MM : SS

OFF

HH : MM

C

P

1

C

P

2

C

C

P

3 P

1 2 3

Machine

Count Fault

HH MM SS ##

!

ON

MM : SS

OFF

HH : MM

C

P

1

C

P

2

C

C

P

3 P

1 2 3

Alarms

In pressure mode indicates that unit is over pressurized or a lubrication cycle was not completed in the user-defined amount of time.

Examine system to determine if you have a plugged or broken line or other component failure, i.e., divider valve, injector.

In cycle mode indicates that a cycle was not completed in the user-defined amount of time.

Press and hold the

RESET button to clear fault.

LED corresponding to the affected sensor input blinks.

Could be more than one sensor alarm at the same time.

Unit has not received the correct number of machine counts in the user defined

Backup Time.

Examine system to determine if the machine sensor is operating properly.

Press and hold the

RESET button to clear fault.

332305B 59

Alarms

System

Fault

HH MM SS ##

!

ON

MM : SS

OFF

HH : MM

C

P

1

C

P

2

C

C

P

3 P

1 2 3

An internal fault has occurred.

Contact Graco Customer

Service.

Motor Current Warning

HH MM SS ##

!

ON

MM : SS

OFF

HH : MM

C

P

1

C

P

2

C

C

P

3 P

1 2 3

The measured motor current is above the recommended operating maximum value. Continued use at excessive motor currents could reduce life or cause permanent damage.

Examine system to make sure it is operating correctly. A blocked line could create excessive motor current

Examine pump to ensure that it is rotating properly.

If necessary, contact

Graco Customer Service.

60 332305B

Temperature Warning

HH MM SS ##

!

ON

MM : SS

OFF

HH : MM

C

P

1

C

P

2

C

C

P

3 P

1 2 3

Alarms

The internal temperature of the unit is out of its recommended operating range.

Ensure the unit is used in the correct operating environment for the specific temperature: -13° F to

158° F (-25° C to 70°C). Use of the unit outside of the recommended temperature range could cause degraded system performance and possible damage.

If necessary contact

Graco Customer Service.

USB Error

HH MM SS ##

!

ON

MM : SS

OFF

HH : MM

C

P

1

C

P

2

C

C

P

3 P

1 2 3

An error occurred during a

DMS operation.

Read the Troubleshooting section of this manual

(page 62) for error num-

bers and fault descriptions.

332305B 61

Troubleshooting

Troubleshooting

Problem

Unit does not power on

Unit does not power on (DC models only)

Cause

Incorrect/loose wiring

Solution

Refer to Installation instructions,

page 8.

Tripped external fuse due to internal component failure

Tripped external fuse due to pumping non-cold weather lubricant in cold weather -13°F (-25°C)

Contact Graco Customer Service.

Replace lubricant with pumpable lubricant, rated for environmental conditions and application.

Unit does not power on (AC models only)

Can’t set desired ON/OFF times

Unit is not operating based on the time that was programmed

Lubricant leaks past seal located on the bottom of the reservoir

Replace fuse.

Tripped internal power supply fuse due to power supply failure

Maximum duty cycle is 33% (2 minutes OFF for each minute ON)

Time entered was misinterpreted as

MM:SS instead of HH:MM (or visa versa)

Contact Graco Customer Service.

Adhere to allowable duty cycle. Contact Graco Customer Support if other duty cycles are required for application.

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.

Replace reservoir.

Reservoir retaining tabs are cracked or broken

Reservoir is being pressurized during filling

Failed motor

Ensure vent hole is not plugged.

If problem persists, contact Graco

Customer Service or your local

Graco distributor for assistance.

Replace unit.

Unit not pumping during ON cycle, but controller lights and functions

Follower plate is not going down

Pump takes several minutes before it begins pumping at the highest pump volume setting (no stroke adjust spacers installed)

Air is trapped in the reservoir between the follower plate and lubricant

Pumping non-cold weather lubricant in cold weather -13°F (-25°C)

Dim display, unit is not operating

Unit indicates a cycle or pressure alarm before the lubrication cycle could complete

Tripped internal, resettable fuse due to internal component failure or sensor short circuit condition

The ON Time was not entered correctly

Add grease following Loading

Grease instructions, page 24. Ensure

air is purged.

Add 1 stroke adjust spacer and adjust lube cycle time to accommodate the difference in pump volume per stroke.

Verify sensor and manual run inputs have not created a short circuit condition. Cycle power.

Refer to programming ON Time,

pages 31 and 52.

62 332305B

Troubleshooting

Problem

In an Injector System without sensor feedback, unit does not vent properly

Display acts erratically

USB Error 00

USB Error 07

USB Error 11

USB Error 12

USB Error 13

Cause Solution

Vent valve time needs to be configured

Faulty cycle/pressure wiring connection to unit

Flash drive was removed during operation

Flash drive unable to mount (initialize)

Refer to Advanced Programming to

set ON Time, page 45.

Unplug cycle/pressure cables from

G3. Plug cables in one at a time to identify the faulty connection.

Keep the flash drive plugged in until the unit has completed the operation.

• Unplug the flash drive and re-install.

• Cycle power and re-install the flash drive.

• Retry using a different flash drive.

If any of the above do not rectify the error, contact Graco Customer Service.

Pump program setting file not found Verify that the pump program setting folder structure and file are stored correctly on the flash drive. See Storing Pump Program Settings to the

Flash Drive, page 37 for instructions.

Pump program settings directory not found.

Verify that the pump program setting folder structure and file are stored correctly on the flash drive. See Storing Pump Program Settings to the

Flash Drive, page 37 for instructions.

Bad pump program settings file The pump programs settings file is corrupt. Restore file to the flash drive.

See Storing Pump Program Settings

to the Flash Drive, page 37 for

instructions.

The following operations can be attempted if another error occurs using the USB.

All other USB errors

• Unplug the flash drive and reinstall.

• Cycle power and re-install the flash drive.

• Retry using a different flash drive.

If any of the above do not rectify the error, contact Graco Customer Service.

332305B 63

Maintenance

Maintenance

Frequency

Daily and at refill

Daily

Daily

Monthly

Zerk Fittings

Component

G3 Pump Unit and Reservoir

Display

External Wiring Harness

Required Maintenance

Keep all fittings clean using a clean dry cloth. Dirt and/or debris can damage pump and/or lubrication system.

Keep pump unit and reservoir clean using a clean dry cloth.

Keep display clean using a clean dry cloth.

Verify external harnesses are secure.

64 332305B

Parts - 2 Liter Models

Parts - 2 Liter Models

332305B

Follower Plate

Models Only

43

44

42

41

40a

34

13

12

3

37

21

31

15

30

40b

Low Level Grease Models Only

45

4 2

35

57

27 1

60

16

36

23

14

18

1

Low Level Oil Models Only

67

66

33

17 3

3

1

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

2

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

3

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

65

Parts - 4 Liter and Larger Models

Parts - 4 Liter and Larger Models

Follower Plate

Models Only

43

44

41

42

40a

66

34

30

61

62

14

31

3 37

21

3

40b

36

35

Low Level Grease Models Only

45

57

27 1

60

13

16

12

18

1

23

15

Low Level Oil Models Only

67

33

17 3

4 2

66

1

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

2

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

3

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

332305B

Parts

Parts

Ref Part Description

1

3

BASE, three pump housing

278142 COVER, bottom, with seal

4

12

13

115477 SCREW, mach, torx pan hd

127079

124396

RECT-RING, included in Kit

571042, 571069, 571179

O-RING, 258, included in Kit

571042, 571044, 571045, 571069,

571179

14 PLATE, ricer

15

16

BEARING, ball

PADDLE, stirring, 2 Liter models without follower plate - models

96G017, 96G019, 96G021,

96G023, 96G025,

96G030-96G032, 96G035-96G037,

96G098, 96G110, 96G125,

96G178, included in Kit 571044

PADDLE, stirring, 4 Liter models without follower plate - models

96G088, 96G092, 96G096,

96G099, 96G103, 96G111,

96G118, 96G126, 96G141,

96G143, 96G145, 96G151,

96G153, 96G155, 96G157,

96G159, 96G160, 96G161,

96G162, 96G181, 96G183,

96G188

PADDLE, stirring, 8 Liter models without follower plate - models

96G089, 96G093, 96G097,

96G100, 96G104, 96G112,

96G119, 96G127, 96G142,

96G144, 96G146, 96G152,

96G154, 96G156, 96G158,

96G177

PADDLE, stirring, 12 Liter models without follower plate - models

96G105, 96G120, 96G164,

96G165

Qty

1

1

9

1

2

1

1

1

1

1

1

Ref Part Description

16 cont

17

18 16F368

PADDLE, stirring, 16 Liter models without follower plate - models

96G106, 96G121, 96G166,

96G168, 96G169, 96G185

PADDLE, stirring, 2 Liter models with follower plate - models

96G018, 96G020, 96G024,

96G026, 96G115, 96G132 included in Kit 571045

PADDLE, stirring, 4Liter models with follower plate - models

96G090, 96G094, 96G113,

96G116, 96G128, 96G133

PUMP, element, included in Kit

571041

SPACER, stroke adjust, included in

Kit 571041

21 278145 PLUG, pump, 3/4-16

23

27

 278136

123025

PADDLE, low level, models

96G017-96G026, 96G030-96G032,

96G035-96G037, 96G088-96G090,

96G092-96G094, 96G096-96G100,

96G103-96G106, 96G110-96G113,

96G115, 96G116,

96G118-96G121, 96G125-96G128,

96G132, 96G133,

96G141-96G146, 96G151-96G162,

96G164-96G166, 96G168,

96G169, 96G177, 96G178,

96G181, 96G183, 96G185,

96G188

SCREW, M6, models

96G017-96G021, 96G023-96G026,

96G030-96G032, 96G035-96G037,

96G088-96G090, 96G092-96G094,

96G096-96G100, 96G103-96G106,

96G110-96G113, 96G115,

96G116, 96G118-96G121,

96G125-96G128, 96G132,

96G133, 96G141-96G146,

96G151-96G162, 96G164-96G166,

96G168, 96G169, 96G177,

96G178, 96G181, 96G183,

96G185, 96G188

Qty

1

1

1

1

2

2

1

1

332305B 67

Parts

Ref Part Description

30

‡ 

31

258697

262463

119228

BOARD, circuit, Max, models

96G017-96G021, 96G023-96G026,

96G030-96G032, 96G035-96G037,

96G088-96G090, 96G092-96G094,

96G096, 96G097,

96G103-96G109, 96G113,

96G118-96G124, 96G128,

96G141-96G146,

96G151, 96G152, 96G155,

96G156, 96G159, 196G160,

96G164, 96G166, 96G168,

96G177, 96G178, 96G181,

96G183

BOARD, circuit, Max, DMS ™ models 96G098-96G100,

96G110-96G112, 96G115,

96G116, 96G125-96G127,

96G132, 96G133, 96G153,

96G154,96G157, 96G158,

96G161, 96G162, 96G165,

96G169, 96G174-96G176,

96G185, 96G186, 96G188

SCREW, machine, flat head, models 96G017-96G021,

96G023-96G026, 96G030-96G032,

96G035-96G037, 96G088-96G090,

96G092-96G094, 96G096-96G100,

96G103-96G113, 96G115,

96G116, 96G118-96G128,

96G132, 96G133,

96G141-96G146, 96G151-96G162,

96G164-96G166, 96G168,

96G169, 96G174-96G178,

96G181, 96G183-96G186, 96G188

33  16A579 LABEL, safety

34 16A073

LABEL, overlay, models

96G017-96G021, 96G023-96G026,

96G030-96G032, 96G035-96G037,

96G088-96G090, 96G092-96G094,

96G096-96G100, 96G103-96G113,

96G115, 96G116,

96G118-96G128, 96G132,

96G133, 96G141-96G146,

96G151-96G162, 96G164-96G166,

96G168, 96G169,

96G174-96G178, 96G181,

96G183-96G186, 96G188

Qty

2

1

Ref Part Description

35

WIPER, stirring, models without follower plate - models 96G017,

96G019, 96G021, 96G023,

96G025, 96G030-96G032,

96G035-96G037, 96G088,

96G089, 96G092, 96G093,

96G096-96G100, 96G103-96G106,

96G110-96G112, 96G118-96G121,

96G125-96G127, 96G141-96G146,

96G151-96G159, 96G160-96G162,

96G164, 96G165, 96G168,

96G169, 96G177, 96G178,

96G181, 96G183, 96G185,

96G188, included in Kit 571044

WIPER, stirring, models with follower plate - models 96G018,

96G020, 96G024, 96G026,

96G090, 96G094, 96G113,

96G115, 96G116, 96G128,

96G132, 96G133 included in Kit

571045

LABEL, brand 36

37 123741

40a 24E984

40b 16G021

40a 24B702

40b 16G020

FITTING, Zerk, grease, not included on models

96G107-96G109, 96G122-96G124,

96G174-96G176, 96G186, 96G188

RESERVOIR, 2 liter, grease,

96G017-96G021, 96G023-96G026,

96G030-96G032, 96G035-96G037,

96G098, 96G110, 96G115,

96G125, 96G132, 96G178, included in Kit 571042, 571069

RESERVOIR, 2 liter, oil, 96G107,

96G122, included in Kit 571179

RESERVOIR, 4 liter, grease,

96G088, 96G090, 96G092,

96G094, 96G096, 96G099,

96G103, 96G111, 96G113,

96G116, 96G118, 96G126,

96G128, 96G133, 96G141,

96G143, 96G145, 96G151,

96G153, 96G155, 96G157,

96G159, 96G160, 96G161,

96G162, 96G181, 96G183, included in Kit 571183

RESERVOIR, 4 liter, oil, 96G108,

96G123, 96G175, 96G188

Qty

1

1

1

1

1

1

1

1

68 332305B

Parts

Ref

40a

40b

40a

40a

41

42

43

44

Part

278139

16F472

45† 24D838

Description

RESERVOIR, 8 liter, grease,

96G089, 96G093, 96G097,

96G100, 96G104, 96G112,

96G119, 96G127, 96G142,

96G144, 96G146, 96G152,

96G154, 96G156, 96G158,

96G177

RESERVOIR, 8 liter, oil, 96G109,

96G124, 96G176, 96G186, included in Kit 571182

RESERVOIR, 12 liter, 96G105,

96G120, 96G164, 96G165

RESERVOIR, 16 liter, 96G106,

96G121, 96G166, 96G168,

96G169, 96G185

SEAL, follower plate, 2 liter models

96G018, 96G020, 96G024,

96G026, 96G115, 96G132

SEAL, follower plate, 4 liter models

96G090, 96G094, 96G113,

96G116, 96G128, 96G133

PLATE, follower, 2 liter models

96G018, 96G020, 96G024,

96G026, 96G115, 96G132

PLATE, follower, 4 liter models

96G090, 96G094, 96G113,

96G116, 96G128, 96G133

ROD, follower plate, 2 liter models

96G018, 96G020, 96G024,

96G026, 96G115, 96G132

ROD, follower, 4 liter models

96G090, 96G094, 96G113,

96G116, 96G128, 96G133

SPRING, compression, 2 liter models 96G018, 96G020, 96G024,

96G026, 96G115, 96G132

SPRING, compression, 4 liter models 96G090, 96G094, 96G113,

96G116, 96G128, 96G133

BAFFLE, low level, 2 liter models

96G017, 96G019, 96G021,

96G023, 96G025, 96G030 -

96G032, 96G035-96G037,

96G098, 96G110, 96G125,

96G178

Qty

1

1

1

1

1

2

1

1

1

1

1

1

Ref

57

58 

Part

24E246

24F836

24F923

24F924

117156

196548

Description

BAFFLE, low level, 4 liter models

96G088, 96G092, 96G096,

96G099, 96G103, 96G111,

96G118, 96G126, 96G141,

96G143, 96G145, 96G151,

96G153, 96G155, 96G157,

96G159, 96G160, 96G161,

96G162, 96G181, 96G183

BAFFLE, low level, 8 liter models

96G089, 96G093, 96G097,

96G100, 96G104, 96G112,

96G119, 96G127, 96G142,

96G144, 96G146, 96G152,

96G154, 96G156, 96G158,

96G177

BAFFLE, low level, 12 liter models

96G105, 96G120, 96G164,

96G165

BAFFLE, low level, 16 liter models

96G106, 96G121, 96G166,

96G168, 96G169, 96G185

BEARING, sleeve, models

96G017-96G021, 96G023-96G026,

96G035-96G037, 96G088-96G090,

96G092-96G094, 96G096-96G100,

96G103-96G106, 96G110-96G113,

96G115, 96G116,

96G118-96G121, 96G125-96G128,

96G132, 96G133,

96G141-96G146, 96G151-96G157,

96G160-96G162, 96G164,

96G165, 96G177, 96G178,

96G181, 96G183, 96G185

LABEL, models 96G019, 96G020.

96G025. 96G026, 96G032,

96G037, 96G092-96G094,

96G118-96G128, 96G132,

96G133, 96G145, 96G146,

96G166, 96G174-96G176, 96G183

Qty

1

1

1

1

1

1

332305B 69

Parts

Ref Part

60 16D984

61

62

66 126417

67 24N806

Description

WASHER, low level, models

96G017-96G021, 96G023-96G026,

96G030-96G032, 96G035-96G037,

96G088-96G090, 96G092-96G094,

96G096-96G100, 96G103-96G106,

96G110-96G113, 96G115,

96G116, 96G118-96G121,

96G125-96G128, 96G132,

96G133, 96G141-96G146,

96G151-96G162, 96G164,

96G165-96G168, 96G177,

96G178, 96G181, 96G183,

96G185

RESERVOIR, mid-section, 8 liter models 96G089, 96G093, 96G097,

96G100, 96G104, 96G109,

96G112, 96G119, 96G124,

96G127, 96G142, 96G144,

96G146, 96G152, 96G154,

96G156, 96G158, 96G176,

96G166. 96G177, 96G186

RESERVOIR, mid-section, 12 liter models 96G105, 96G120, 96G164,

96G165

RESERVOIR, mid-section, 16 liter models 96G106, 96G121, 96G166,

96G168, 96G169, 96G185

ADAPTER, reservoir, models

96G088-96G090, 96G092-96G094,

96G096, 96G097,

96G099-96G100, 96G103-96G106,

96G108, 96G109,

96G111-96G113, 96G116,

96G118-96G121, 96G123,

96G124, 96G126-96G128,

96G133, 96G141-96G146,

96G151-96G162, 96G164-96G166,

96G168, 96G169,

96G175-96G177, 96G181,

96G183, 96G185, 96G186

NUT, oil, models 96G107, 96G108,

96G109, 96G122, 96G123,

96G124, 96G175, 96G176,

96G186

FLOAT, oil, models 96G107,

96G108, 96G109, 96G122, 96G123,

96G124, 96G175, 96G176, 96G186,

96G188

Qty

2

1

2

3

1

Ref Part

200

201

202

Description

126217

126218

126219

126220

CABLE,15 ft (4.5 m), SOOW w/7pos, 3 pin, 90 deg

CABLE, 15 ft (4.5 m), SOOW w/7 pos, 5 pin, 90 deg

CABLE, 20 ft (6.1 m), SOOW, w/7 pos, 5 pin, 90 deg

CABLE, 30 ft (9.1m) SOOW, w/7 pos, 5 pin, 90 deg

16U790 CABLE, DIN, bare)

124300

124333

124301

CABLE, M12, 15 ft., 4 wire, straight male to flying leads

CABLE, M12, 15 ft., 4 wire, straight male to female

CONNECTOR, Eurofast, fem, straight, 4Pin

124594 CONNECTOR, Eurofast, 4 Pin

124595 CONNECTOR, Eurofast, 5 Pin

Qty

1

1

1

1

1

1

1

1

1

 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

‡  Also order Ref 31, Part No. 119228 and Ref 34, Part

No. 16A073

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

70 332305B

Parts

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 pressure relief valve a means of relieving pressure in day-to-day, normal cycle operation. a b ti15644 a = adjustment screw

The pressure adjustment screw will require periodic adjustments. b = locking nut

Whenever the valve is set/adjusted (after the set point is found) it is important to ensure that the valve is not bottomed 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.

Part

16C807 

563156

563157

563158

563159

563160

563161

563190

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 MPa,

51.71 bar)

VALVE, pressure relief, 1000 psi (6.89 MPa,

68.95 bar)

VALVE, pressure relief, 1500 psi (10.34 MPa,

103.42 bar)

VALVE, pressure relief, 2000 psi (13.78 MPa,

137.89 bar)

VALVE, pressure relief, 2500 psi (17.23 MPa,

172.36 bar)

VALVE, pressure relief, 3000 psi (20.68 MPa,

206.84 bar)

VALVE, pressure relief, 5500 psi (37.92 MPa,

379.21 bar)

Qty

1

1

1

1

1

1

1

1

Fuses

Part Description

571039 FUSE, 12 volt DC

571040 FUSE, 24 volt DC

Qty

1

1

Installation and Repair Kits

Kit No.

Description

Manual

Number

571026 KIT, output union, 3 pump

571063 KIT, output union, 2 pump

571028

571071

KIT, return to reservoir NPT, includes pressure relief valve 16C807

KIT, return to reservoir BSPP, includes pressure relief valve 16C807

571030 KIT, remote manual run, 12 volt DC

3A0523

3A0525

571031 KIT, remote manual run, 24 volt DC

571032

KIT, remote manual run, 12 volt DC, with cable

3A0528

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

571069

571044

571045

571046

571047

KIT, repair, 2 liter reservoir, 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

571070 KIT, output, adapter, BSPP

571060 KIT, fill, zerk, leakproof

571179

KIT, repair, reservoir oil, 2 liter models, includes Ref 13, 36, 40b

571182

571183

KIT, repair, reservoir, oil 4 liter models, includes Ref 13, 36, 40b

KIT, repair, reservoir, grease, 4 liter models, includes Ref 13, 36, 40b

3A0534

3A0535

3A0522

NA

3A0534

332305B 71

Technical Data

Technical Data

A Maximum Working Pressure

Power

100-240 VAC

12 VDC

24 VDC

Outputs - Alarm Relay

Rated Load

Max Operation Voltage

Max Operating Current

Max Switching Capacity

Min Permissible Load

Outputs - Vent Valve

Required Vent Valve Type

Output Voltage

100/240 VAC

12 VDC

24 VDC

Max Operating Current

Max Operating Power

Inputs - Cycle Pressure, 1, 2, 3, Machine Count

Required Switch Type

Sensor Voltage

100/240 VAC

12 VDC

24 VDC

Load Current

100/240 VAC

12 VDC

24 VDC

Maximum Residual Voltage

100/240 VAC

12 VDC

24 VDC

Maximum Off Current

100/240 VAC

12 VDC

24 VDC

Input Impedance

Response Time

Cycle Rate

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 (1ms)

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

Resistive: 0.4 A at 125 VAC, 2 A at 30 VDC

Inductive: 0.2 A at 125 VAC, 1 A at 30 VDC

Resistive: 250 VAC, 220 VAC

Inductive: 250 VAC, 220 VDC

Resistive: 3 A (AC), 3A (DC)

Inductive: 1.5 A (AC), 1.5 A (DC)

Resistive: 50 VA, 60 W

Inductive: 25 VA, 30 W

Resistive: 10

µ

A, 10m VDC

Inductive: 10

µ

A, 10m VDC

Normally closed

24 VDC

Input Voltage

Input Voltage

2 A

48 W

Normally open (sink, source, or dry contact)

24 VDC

Input Voltage

Input Voltage

22mA @ 24 VDC

11mA @ 12 VDC

22mA @ 24 VDC

4 V

2 V

4 V

1.5 mA

1 mA

1.5 mA

1.1 K

60 ms

8.0 Hz (50% duty cycle)

72 332305B

Technical Data

Fluid

Grease Models

Oil Models

Pumps

Pump Output

Pump Outlet

Reservoir Size

IP Rating

Sensor Inputs

Ambient Temps

Weight (Dry - includes power cord and plug)

Without follower plate

With follower plate

Wetted Parts

Sound Data

Grease NLGI 000 - #2

At least 40 cSt oil.

Up to 3

0.12 in.

3 (2 cm 3 ) / minute per outlet - 2 spacers

0.18 in.

3 (3 cm 3 ) / minute per outlet - 1 spacer

0.25 in.

3 (4 cm 3 ) / minute per outlet - 0 spacers

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

2, 4, 8, 12, 16 Liters

IP69K

3 (any of pressure or cycle)

1 (machine count)

-40°F - 158°F (-40°C to 70°C)

13.3 lbs (6.03 kg)

14.2 lbs (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 lubricated acetal, aluminum, PTFE, Grillamid

<60 dB

Dimensions

Model

2L

4L

8L

12L

16L

Inches

13.25

14.50

18.50

23.00

27.50

Height cm

33.65

36.83

47.00

58.42

69.85

Inches

8.00

9.25

9.25

9.25

9.25

Width cm

20.32

23.50

23.50

23.50

23.50

Inches

9.00

10.00

10.00

10.00

10.00

Depth cm

22.86

25.40

25.40

25.40

25.40

332305B 73

Technical Data

Mounting Pattern

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

Option 1

0.367inch

9.3

mm

7.0

8 7 inch

1 8 0.0

mm

2x Ø 0.366

inch

9.3

mm

1.1

8 0 inch

30.0

mm

3.26

8 inch

8 3.0

mm

Option 2

2x Ø 0.366

inch

9.3

mm

0.722

inch

1 8 .3

mm

3.544

inch

90.0

mm

6.37

8 inch

162.0

mm

0.70

8 inch

1 8 .0

mm

3.740

inch

95.0

mm

3.1

8 9 inch

8 1.0

mm

F IG . 37

74 332305B

Notes

Notes

332305B 75

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

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 332305

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

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