Graco 332305T, G3 Max Automatic Lubrication Pump Owner's Manual

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Graco 332305T, G3 Max Automatic Lubrication Pump Owner's Manual | Manualzz

Instructions

G3™ Max Automatic

Lubrication Pump

332305T

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 (classified) locations.

Part Nos., page 3

5100 psi (35.1 MPa, 351.6 bar) Pump Output Pressure

5000 psi (34.3 MPa, 344.8 bar) Fill Inlet Pressure

Important Safety Instructions

Read all warnings and instructions in this manual before using the equipment.

Save these instructions.

Conforms to ANSI/UL 73

Certified to CAN/CSA

C22.2 No 68

3132066

100-240VAC Pumps ONLY.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 10

Typical Installation - With Remote Fill Manifold . 11

Optional Installation - Without Remote

Fill Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 12

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Unpack the Pump . . . . . . . . . . . . . . . . . . . . . . . 13

System Configuration and Wiring . . . . . . . . . . . 14

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

Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Connect to Auxiliary Fittings . . . . . . . . . . . . . . . 23

Set Pump Outlet Volume . . . . . . . . . . . . . . . . . . 24

Load Pump with Grease . . . . . . . . . . . . . . . . . . 24

Auto-Fill Shut Off . . . . . . . . . . . . . . . . . . . . . . . . 27

Fill the Oil Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Prime the Pump . . . . . . . . . . . . . . . . . . . . . . . . . 29

Quick Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . . 31

Max Model Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Control Panel Overview (F

IG

. 34) . . . . . . . . . . . . 32

Program the Max Model . . . . . . . . . . . . . . . . . . 33

PUMP OFF / REST Setup . . . . . . . . . . . . . . . . . 38

DMS ™ Models Only. . . . . . . . . . . . . . . . . . . . . . 41

Store Pump Program Settings to the

Flash Drive. . . . . . . . . . . . . . . . . . . . . . . . . . 41

Upload Pump Program Settings to the Pump . . 42

Operation / Data Log . . . . . . . . . . . . . . . . . . . . . . . 43

System Event Log . . . . . . . . . . . . . . . . . . . . . . . 43

Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Functional Summary . . . . . . . . . . . . . . . . . . . . . 46

Technical Summary . . . . . . . . . . . . . . . . . . . . . . 48

Advanced Programming . . . . . . . . . . . . . . . . . . . . 49

Models with Firmware 6.03 and later. DMS

Models with Firmware 7.07 and later. . . . . . 55

Models with Firmware 6.06 and later for non-DMS models. Models with Firmware

7.09 and later for DMS models . . . . . . . . . . 56

Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Time Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Alarms: Firmware Versions 6.01 and Below. . . . . 63

Fault / Warning Scenarios . . . . . . . . . . . . . . . . . 63

Alarms: Firmware Versions 6.02 and Above. . . . . 68

Fault / Warning Scenarios . . . . . . . . . . . . . . . . . 68

Fault/Warning Scenarios for Firmware Versions

6.06 and Later for Non-DMS Models and

7.09 and later for DMS Models . . . . . . . . . . . . 75

Recycling and Disposal . . . . . . . . . . . . . . . . . . . . . 76

End of Product Life. . . . . . . . . . . . . . . . . . . . . . . 76

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Parts - 2 Liter Models . . . . . . . . . . . . . . . . . . . . . . . 81

Parts - 4 Liter and Larger Models . . . . . . . . . . . . . 82

Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Mounting Pattern . . . . . . . . . . . . . . . . . . . . . . . . 87

Technical Specifications . . . . . . . . . . . . . . . . . . . . 88

California Proposition 65 . . . . . . . . . . . . . . . . . . . . 89

Graco Standard Warranty. . . . . . . . . . . . . . . . . . . . 90

Graco Information . . . . . . . . . . . . . . . . . . . . . . . 90

332305T

Part / Model Numbers

Part / Model Numbers

The Part Number is a six-digit unique number that is only used to order the G3 Pump. The configured Model Num ber identifies the distinct features of a specific G3 Pump. To help you understand each component that makes up the Model Number see

Understanding the Model Number , page 5. The tables below shows the relationship

between each Part Number and its related Model Number.

2 Liter Models 4 Liter Models

Part Model Numbers

96G107

96G110

96G115

96G122

96G125

96G132

96G174

96G178

96G190

96G206

96G300

96G305

96G312

96G315

96G026

96G030

96G031

96G032

96G035

96G036

96G037

96G098

96G017

96G018

96G019

96G020

96G021

96G023

96G024

96G025

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

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

G3-G-ACMX-2L0L00-1D0V0000

G3-G-ACMX-2LFL00-1D0V0000

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

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

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

G3-G-ACMX-2L0L00-1DMVA2R3

G3-G-ACMX-2LFL00-1DMVA2R3

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

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

G3-G-ACMX-2L0L00-1D000000

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

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

G3-G-ACMX-2L0L00-1D00A000

G3-G-12MX-2L0L00-UDMVA1R2

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

G3-G-24MX-2L0L00-UDMVA1R2

G3-G-24MX-2LFL00-UDMVA1R2

G3-A-ACMX-2L0L00-1DMVA2R3

G3-G-ACMX-2L0L00-UDMVA1R2

G3-G-ACMX-2LFL00-UDMVA1R2

G3-A-ACMX-2L0L00-UDMVA1R2

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

G3-A-24MX-2L0L00-UDMVA1R2

G3-G-24MX-2L0L07-0D00A000

G3-G-24MX-2L0L00-1DM0A2R3

G3-G-ACMX-2L0L00-1DM0A2R3

G3-G-24MX-2L0L00-UDM0A1R2

G3-G-ACMX-2L0L00-UDM0A1R2

X

X

X

X

X

X

X

X

X

X

X

X

Part 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

96G212 G3-G-24MX-4LAL05-10CV0000

96G218 G3-G-12MX-4LFL00-10MVA2R3

96G232 G3-G-12MX-4L0005-10CV0000

96G274 G3-G-24MX-4LFL05-10CV0000

96G293 G3-G-ACMX-4LFL00-1D00A000

96G301 G3-G-24MX-4L0L00-1DM0A2R3

96G306 G3-G-ACMX-4L0L00-1DM0A2R3

X

X

X

X

X

X

X

X

X

X

X

X

332305T 3

4

Part / Model Numbers

96G310 G3-A-ACMX-4L0L00-1DM0A2R3

96G313 G3-G-24MX-4L0L00-UDM0A1R2

96G316 G3-G-ACMX-4L0L00-UDM0A1R2

96G318 G3-G-ACMX-4LFL00-UDM0A1R2

8 Liter Models

Part 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

96G191 G3-G-24MX-8L0L05-10CV02M3

96G195 G3-A-24MX-8L0L05-U0C0010M

96G197 G3-G-ACMX-8LFL00-1DMVA2R3

96G209 G3-G-ACMX-8LAL00-1DV00000

96G215 G3-G-24MX-8LAL05-10CV0000

96G216 G3-G-24MX-8L0L08-10CV00000

96G259 G3-G-24MX-8LFL05-U0CV0100

96G263 G3-G-ACMX-8LAL00-1DMVA2R3

96G266 G3-G-24MX-8LLL05-U0CV0100

96G269 G3-G-ACMX-8LLL00-UDMVA1R2

96G275 G3-G-24MX-8LFL05-10CV0000

X

X

X

X

X

X

X

X

X

X

X

X

96G288 G3-G-24MX-8LLL00-1D00A000

96G289 G3-G-24MX-8L0L08-10CV0000

96G292 G3-G-24MX-8LFl00-1DMVA2R3

96G302 G3-G-24MX-8L0L00-1DM0A2R3

96G307 G3-G-ACMX-8L0L00-1DM0A2R3

96G311 G3-A-ACMX-8L0L00-1DM0A2R3

96G314 G3-G-24MX-8L0L00-UDM0A1R2

96G317 G3-G-ACMX-8L0L00-UDM0A1R2

12 Liter Models

Part Model Numbers

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

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

96G164 G3-G-24MX-120L05-10CV0000

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

96G231 G3-G-12MX-120L08-V0C0010M

96G246 G3-G-24MX-120L08-U0C0010M

96G254 G3-G-12MX-120L08-U0C0010M

96G260 G3-G-24MX-12AL00-UDMVA1R2

96G303 G3-G-24MX-120L00-1DM0A2R3

96G308 G3-G-ACMX-120L00-1DM0A2R3

16 Liter Models

Part Model Numbers

96G106 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

96G201 G3-A-ACMX-160L00-UDMVA1R2

96G219 G3-G-24MX-160L08-10CV0000

96G235 G3-G-ACMX-160L00-UDMVA1R2

96G252 G3-G-12MX-160L00-UDMVA1R2

96G267 G3-G-24MX-16LL05-U0CV0100

96G304 G3-G-24MX-160L00-1DM0A2R3

96G309 G3-G-ACMX-160L00-1DM0A2R3

X

X

X

X

X

X

X

X

X

X

332305T

Part / Model Numbers

Understanding the Model Number

Use the Code Sample provided below to identify each component’s location in the Model Number. The options for each component that make up the code are provided on the lists below.

NOTE: Other pump configurations are available that are not documented in this manual. Contact Graco Customer

Service or your local Graco distributor for assistance.

Code Sample:

G 3 a

M X 0 0 0 0 0 0 b b c c - d d e f g g - h i j k m n p q

Code a: Pump Fluid Type

• G = Grease

• A = Oil

Code bb: Power Source

• 12 = 12 Volts DC

• 24 = 24 Volts DC

• AC = 100 - 240 Volts AC

Code cc: Operation Control

• MX= Max Controller

Code dd: Reservoir Capacity (Liters)

• 2L = 2 Liters

• 4L = 4 Liters

• 8L = 8 Liters

• 12 = 12 Liters

• 16 = 16 Liters

Code e: Reservoir Feature

• F = Follower Plate Installed

• 0 = No Follower Plate

• A = Auto-Fill Shut Off

• L = Top Fill

Code f: Low Level Option

• L = Low Level with Controller

• 0 = No Low Level monitoring

Code gg: Options

• 00 = No Options

• 03 = Powered Alarm Contact

• 05 = 5 Pin CPC power cable

• 07 = No Power Cord

• 08 = Normally open vent valve with alarm, manual run, and low level in CPC

Code h, i, j, k, m, n, p, q

NOTE: Codes h - q 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 ™ Model

h i m n j k p q

F IG . 1

332305T 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 symbols refer to procedure-specific risks.

When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings.

Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power cord before servicing equipment.

• Connect only to grounded electrical outlets.

• Use only 3-wire extension cords.

• Ensure ground prongs are intact on power and extension cords.

• 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 Specifications in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical

Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request Safety Data Sheets (SDSs) 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.

332305T

332305T

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 the Pressure Relief Procedure in this manual before servicing.

PLASTIC PARTS CLEANING SOLVENT HAZARD

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

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

• See Technical Specifications in all equipment manuals for materials of construction. Consult the solvent manufacturer for information and recommendations about compatibility.

7

8

Warnings

WARNING

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.

• 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. 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.

332305T

Installation

Installation

Component Identification

Oil Models

M

Grease Models

A

Top Fill Models

P

DMS TM Models

E

Grease Models with Follower

Plate

Q

K

L

I

Auto-Fill Shut Off Models

N

J

D

H

96GXXX

G3-G-24MX-2L0A00-L0C00000

F

B

F

IG

. 2

Key:

A Reservoir

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

C Pressure Relief Valve (Not included (not shown) / required for each outlet - Available from Graco. See Parts, page

85.)

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 . 21, page 24)

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

Available from Graco. See Parts, page 85.)

H Control Panel

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

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

page 5, Understanding the Model Number

, for details)

332305T

K Follower Plate (grease models only / not available on all grease models)

L Vent Hole for Follower Plate (grease models only / not available on all grease models)

M Fill cap (oil models only)

N Auto-Fill Shut Off

P Top Fill Lid

Q USB Port (DMS models only)

R Power Cord (not shown)

9

Installation

Typical Installation

Series Progressive Divider Valve

B

C

D

E

A

F IG . 3

Injector Installations

F

H B E

A G

D

F

C

F

IG

. 4

Key

A Connected to fused power source

B Pressure relief valve (Not included/ required for each out let - user supplied. See Parts, page 85)

C Supply Hose (user supplied)

D Series progressive divider valves (Divider Installations)

- Injectors (Injector Installations)

E To lube points

F - Proximity Switch (Divider Installations)

- Pressure switch (Injector Installations)

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

Parts , page 83.)

H Return to reservoir

10 332305T

N B

Installation

Typical Installation - With Remote Fill Manifold

The installation shown is only a guide for selecting and installing system components. Contact your Graco distributor for assistance in planning a system to suit your needs.

R

H

F

J

D

C

S

T

M P

Q

E

K

L

A

F IG . 5

Key:

A G3 Pump

B Auto-Fill Shut Off Valve

C Auto-Fill Inlet

D G3 Reservoir

E Remote Fill Reservoir

F Remote Fill Pump

G Supply Hose (user supplied)

H Air Supply to Refill Pump

J Supply Hose (user supplied)

K Pressure Relief Valve

L Drain Hose

M Fill Coupler/Inlet (quick disconnect)

N Fill Manifold

P Fill Manifold Outlet

Q Fill Manifold Vent Port

R Pressure Gauge

S Pressure Regulator and Gauge

T Pressure Relief Knob

❖ To relieve the stall pressure in the fill line a fill manifold (N) must be installed in the system.

332305T 11

Installation

Optional Installation - Without Remote Fill Manifold

The installation shown is only a guide for selecting and installing system components. Contact your Graco distribu tor for assistance in planning a system to suit your needs.

NOTE: The remote filling station pump stalls (dead-heads) when the reservoir is full. If the pump does not stall

(dead-head) there is a leak in the system.

H

F

U

J

C

B

D

A

S

V

Y

L

E

F IG . 6

Key:

A G3 Pump

B Auto-Fill Shut Off Valve

C Auto-Fill Inlet

D G3 Reservoir

E Remote Fill Reservoir

F Remote Fill Pump

H Relief Valve

J Supply Hose (user supplied)

L Drain Tube

L1 Option - To reservoir

L2 Option - To overflow container

S Pressure Regulator and Gauge

U Pressure Relief Valve

V Quick Disconnect

W Overflow Container

Y Supply Hose Pressure Relief Valve ❖

❖ To relieve the stall pressure in the fill line a ball valve (Y) must be installed in the system.

L1

L2

W

12 332305T

Installation

Installation

Unpack the Pump

NOTICE

To prevent equipment damage, observe precautions for handling electrostatic sensitive devices. Touch ground before handling pump.

The pump module was carefully packaged for shipment by Graco. When the package arrives, perform the fol lowing procedure to unpack the units:

1. Inspect the shipping box carefully for shipping damage. Contact the carrier promptly if damage is discovered.

2. Unseal the box and inspect the contents carefully.

There should not be any damaged parts.

3. Compare the packing slip against all items included in the box. Any shortages or other inspection problems should be reported immediately.

Choose an Installation Location

AUTOMATIC SYSTEM ACTIVATION HAZARD

The system is equipped with an automatic timer that activates the pump lubrication system when power is connected or when exiting the programming func tion. Unexpected activation of the system could result in serious injury, including skin injection and amputation.

Before you install or remove the lubrication pump from the system, disconnect and isolate all power supplies and relieve all pressure.

• 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 mounting hole layouts provided in the Mounting Pattern section of this manual,

page 90. No other installation configuration

should be used.

• Use designated mounting holes and provided configurations only.

• Always mount the G3 oil models upright.

• Mount top fill G3 pump models so that there is a a minimum clearance of four inches (4.0 in.)

(10.2 cm) above the reservoir to allow for lid removal and filling.

• If the G3 grease model is going to be operated in a tilted or inverted position for any period of time, you must use a model that includes a fol lower plate, otherwise the G3 must be mounted upright. Refer to your model number to confirm if a follower plate was installed on your pump.

See page 5, Understanding the Model Num ber

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. See table below for bracket information.

• In high vibration environments, additional isola tion at mounting point is necessary. See table below.

• AC pumps are not recommended when high vibration or shock is present.

Part No Description

571159 Reservoir bracket and strap

125910 L-Bracket for pump

127665 USP to G-Series mounting bracket

132187 Isolator mounting kit

332305T 13

Installation

System Configuration and

Wiring

Grounding

The equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static spark ing can cause fumes to ignite or explode. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current.

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 ser viceman.

• 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 specifica tions.

• it must be an approved, 3-wire grounding type attachment plug.

• it must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances.

• when repair or replacement of the power cord or plug is required, do not connect the grounding wire to either flat blade terminal.

Fuses

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 current must be installed in line with the power entry to the equipment.

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 Graco Kit No.

12 VDC 7.5 A 571039

24 VDC 4 A 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 con nector does not exit the unit in the UP direction.

• Use a corrosion preventative electrical grease on all contacts.

14 332305T

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 associ ated 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.

See Advanced Menu Options A7, A9, or A11 to modify the behavior of the alarm output or low level output.

Unit in OFF Mode

Unit in ON Mode

Warning Condition

Fault Condition

Alarm Output

(via DIN alarm relay connector)

Deactivated (off)

Deactivated (off)

Activated (on)

Toggles On and Off once per second

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

Tri-Color Remote

Illumination

(via M12 Connector)

Off

Green

Yellow

Red

Outputs (“08” option) (via 5 wire CPC)

Low Level Warning

Low Level Fault

Pin 4

Alarm

Pin 7

Low Level

Activated (On) Activated (On)

Toggles On and Off once per second Activated (On)

332305T 15

Installation

Alarm Relay Response

Output Tied to Common

No Faults or

Warnings

N.O.

N.C.

Warning

(Advanced

Programming

Setting A11 OFF)

N.O.

N.C.

Fault

(Advanced

Programming A7

OFF)

N.O.

N.C.

Fault

(Advanced

Programming

Setting A7 ON)

N.O.

N.C.

1 second

Wire and Installation Diagrams

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

Diagram Symbol Page #

Power DIN AC

17

Power DIN DC

Power CPC DC

17

18

Inputs (M12)

19

Vent Valve Outputs

Alarm Outputs

Illuminated Manual Run Input

20

20

Kits: 571030, 571031,

571032, 571033

16 332305T

Installation

Power DIN AC - 15 foot: Part No.

16U790

Pin and Related Wire Color (F

IG

. 7)

Pin Pin Name

1

2

3

Line

Neutral

Color

Black

White

Not Used Not Used

Ground Green

Power DIN DC - 15 foot

Pin and Related Wire Color (F

IG

. 8)

Pin

1

2

3

Pin Name

-VDC

+VDC

Not Used

Color

Black

White

Not Used

Not Used Green

F

IG

. 7

332305T

F IG . 8

17

Installation

Power CPC DC -2 Wire

Part No.: 127783: 15 ft. (4.5 m)

Pin and Related Wire Color (F

IG

. 9)

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

Power CPC DC - 5 Wire

Part No.: 127780: 15 ft (4.5 m)

Part No.: 127781: 20 ft (6.1 m)

Part No.: 127782: 30 ft (9.1 m)

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. Con tact your local Graco distributor or Graco Customer

Service for additional information about these kits.

Pin and Related Wire Color (F

IG

. 10)

Pin Pin Name

3

4

1

2

5

6

7

Not Used

-VDC

+VDC

LIGHT

Manual Run

Switch

Not Used

Not Used

Color

Not Used

Black

Red

White

Orange

Not Used

Green

F IG . 10

F IG . 9

18 332305T

Pin and Related Wire Color (F

IG

. 11)

Wiring for “08” Option

CPC Pin

5

6

7

3

4

1

2

Pin Name

Not Used

-VDC/Com

+VDC

Alarm

Manual

Not Used

Low Level Warning

Wire Color

Not Used

Black

Red

White

Orange

Not Used

Green

Installation

Inputs (M12)

See

Technical Specifications , page

88 for ratings.

F IG . 12

F IG . 11

332305T 19

Installation ratings.

Vent Valve Outputs

See

Technical Specifications , page 88 for

Alarm Outputs

DC example shown. See

Technical Specifi cations , page 88 for ratings.

F IG . 13

1

20

1.

F

IG

. 14

332305T

Installation

Part No. 124333: Cable Pin Out (M12) for 5m cable

Wire Colors (F

IG

. 15)

Item No. Color

3

4

1

2

Brown

White

Blue

Black

Part No. 124300: Male Flying Lead Pin Out

(M12)

Wire Colors (F

IG

. 16)

Item No. Color

1

2

3

4

Brown

White

Blue

Black

F IG . 15

332305T

F IG . 16

Part No. 124301: 4 Pin (M12) Female Field

Wireable Connector for 6-8 mm Cable

F IG . 17

21

Installation

Part No. 124594: 4 Pin (M12) Male Field

Wireable Connector for 6-8 mm Cable

F

IG

. 18

NOTE: Field wireable connectors are for sensors with integrated cable.

Part No. 124595: 5 Pin (M12) Male Field

Wireable Connector for 8-11 mm Cable

F IG . 19

NOTE: Field wireable connectors are for sensors with integrated cable.

22 332305T

Setup

Setup

Pressure Relief

Follow the Pressure Relief Procedure whenever you see this symbol.

Connect 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 dispensing and before cleaning, checking, or servicing the equipment.

Relieve pressure at the pump element using two wrenches working in opposite directions on the 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. Repeat for each pump element installed (F IG . 20).

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 fit tings such as fill ports and pump element. Attaching unsupported equipment to these fitting can result in irreparable housing damage.

• Always use two wrenches working in opposite directions when connecting anything to pump ele ment or auxiliary fittings. See F IG . 20 for an exam ple.

• 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 alle viate 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 any com ponent installed in the system. See Technical

Specifications , page 88.

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

NOTE: A pressure relief valve can be purchased from

Graco. See

Parts , page 83.

F IG . 20

332305T 23

Setup

Set Pump Outlet Volume

NOTE:

• Before making any adjustments to pump volume,

Relieve Pressure

following procedure on page 23.

• Only use Graco supplied spacers to control output volume.

1. Use a wrench to turn pump element counter-clock wise to loosen. Do not remove entire pump ele ment. 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 . 21).

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

NOTE:

• The amount of dispensed volume can vary depend ing on external conditions such as lubricant tem perature and back pressure from downstream connections.

• Use of these volume adjustment in conjunction with setting the ON time of the pump will allow for con trol of the output volume.

• Use these volume adjustments as a starting point and adjust as necessary to ensure desired lubrica tion dispense.

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

D

F IG . 22

F IG . 21

Load Pump with 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 . 24).

• Do not operate G3 without reservoir attached.

NOTICE

• Always clean inlet fitting (D) (F IG . 22) with a clean dry cloth prior to filling reservoir. Dirt and/or debris can damage pump and/or lubri cation system.

• Care must be used when filling the reservoir using a pneumatic or electric transfer pump to not pressurize and break the reservoir.

24 332305T

Setup

Models without a follower plate:

1. Connect fill hose to Zerk Inlet Fill Fitting (D) (F IG .

23).

Models with Top Fill

E

D

F IG . 23

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

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 lid removed.

• Disconnect power before removing lid.

1. Disconnect the power from the equipment.

NOTE : If battery disconnect is not available, remove the power cord (F

IG

. 25).

F IG . 24

4. Remove fill hose.

332305T

F

IG

. 25

2. Clean the top of the lid and the area around the top of the reservoir to ensure that no debris falls into the reservoir when the lid is removed.

3. Turn the lid counterclockwise to remove.

4. Place the lid in a clean area to avoid debris getting into the inside of the lid or threads.

5. Fill the reservoir with new clean grease.

6. Make sure that no contaminants enter the reservoir.

25

Setup

NOTICE

Any debris or dirt accidentally introduced into the res ervoir should be removed immediately. Do not allow the pump to operate until any debris or dirt are removed.

Operating the pump with debris or dirt in the reservoir, may damage the pump, down stream equipment, and bearings.

7. Clean the threads on the reservoir and the lid.

8. Replace the lid onto the reservoir, turning clockwise

(approximately 1 3/4 turns).

9. Reconnect the power to the equipment.

Models with a follower plate:

1. Connect fill hose to inlet fitting (D) (F IG . 23).

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

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 . 26) and the majority of air is expelled from the reservoir.

NOTE: The vent port, located in rear of reservoir, should not be used as an overfill port/indicator/

Vent

F IG . 26

4. Turn off the air supply (H) to the refill pump (F).

5. Remove the fill hose.

26 332305T

Setup

Auto-Fill Shut Off

Load Grease

To ensure optimal performance from the G3:

• Only use NLGI #000 - #2 greases appropriate for your application, automatic dispensing, and the temperature. Consult with machine and lube manu facturer for details.

• Do not overfill.

• Do not operate G3 without reservoir attached.

NOTICE

Care must be used when filling the reservoir using a pneumatic or electric transfer pump to not pressur ize and break the reservoir.

Change Greases

When changing greases, always use compatible fluids or greases.

Remote Fill with Remote Fill Manifold

The remote filling station pump stalls (dead-heads) when the reservoir is full, causing the supply system pressure to rise to the maximum output pressure of the filling station pump. To help prevent equipment damage or serious injury caused by pressurized fluid, such as skin injection or injury from splashing fluid, always use a remote filling station pump with a maxi mum output pressure of 5100 psi (35.1 MPa,

351.6 bar) and use supply hoses with a minimum pressure rating of 5100 psi (35.1 MPa, 351.6 bar).

COMPONENT RUPTURE HAZARD

The maximum working pressure of each component in the system may not be the same. To reduce the risk of over-pressurizing any component in the sys tem, be sure you know the maximum working pres sure of each component. Never exceed the maximum working pressure of the lowest rated com ponent in the system. Over-pressurizing any compo nent can result in rupture, fire, explosion, property damage and serious injury.

Regulate input pressure to the remote fill pump so that no fluid line, component or accessory is over pressurized.

The reference letters used in the following instructions refer to F IG . 5, page 11.

The fill valve is used to relieve pressure in the refill line and to reset the Auto Fill Shut Off. See Fill Valve instruction manual 333393. Graco fill valve, part no.

77X542 is available. Contact your local Graco distribu tor.

1. Pull out and hold the Pressure Relief Knob (T) long enough to relieve line pressure between Fill Mani fold (N) and Auto-Fill Shut Off Valve (B).

2. Verify the Auto-Fill Shut Off (B) pin is down, indicat ing it is reset (F IG . 27). pin down

332305T

F IG . 27

3. Remove yellow Dust Cover from Fill Coupler (M).

27

Setup

4. Connect Supply Hose (J) between the Remote Fill ing Station Pump (F) and Fill Coupler port marked with an “I”.

5. Start Remote Filling Station Pump (F).

6. When the G3 Reservoir (D) is filled:

• the Remote Filling Station Pump (F) stalls

(dead-heads),

• the Auto-Fill Shut Off (B) pin pops up as shown in F IG . 28,

• the Pressure Gauge (R) rises to the fill pump’s set pressure.

NOTE: If the pump does not stall (dead-head) there is a leak in the system.

pin up

9. Disconnect Supply Hose (J) at Fill Coupler (M).

10. Replace yellow Dust Cover over Fill Coupler (M).

Remote Fill without Remote Fill Manifold

The reference letters used in the following instructions refer to F IG . 6, page 12.

1. A supply hose pressure relief valve (Y) and overflow container (W) (for collecting excess fluid that drains during pressure relief) must be installed in an easily accessible location between the remote filling sta tion pump (F) and the Auto-Fill Shut Off (B). This pressure relief valve is used to relieve pressure in the refill line and to reset the Auto-Fill Shut Off. See

Typical Installation , starting on page 10.

A Pressure Relief Kit: 247902 is available from

Graco. Contact your distributor or Graco Customer

Service for additional information about this kit.

2. Connect Supply Hose (J) at Quick Connect (V).

3. Turn on remote filling station pump (F) and fill the

G3 reservoir (D) until the indicator pin on the

Auto-Fill Valve pushes up as shown in F IG . 29. The pressure in the refill pump (F) builds and the pump stalls.

pin up

F IG . 28

NO

7. Turn off the Remote Filling Station Pump (F).

8. Pull out and hold the Pressure Relief Knob (T) long enough to relieve line pressure between Fill Mani fold (N) and Auto-Fill Shut Off Valve (B) and between Remote Filling Station Pump (F) and Fill

Manifold (N).

NOTE: The length of time it takes to vent varies depending on the system design and installation. In some installations it may be necessary to repeat Step 8 to ensure pressure is relieved.

F IG . 29

4. Turn off the air supply (H) to pump (F).

5. Relieve remote filling station pump pressure using

28 332305T

Setup

Remote Filling Station Pressure Relief

The reference letters used in the following instructions refer to F

IG

. 6, page 12.

The following Pressure Relief Procedure is only used with the Auto-Fill Shut Off Valve to relieve remote filling station and lubricant supply line pressure.

Fill the Oil Unit

• Only use oil appropriate for your application, auto matic dispensing, and the equipment’s operating temperature. Consult with machine and lube manu facturer for details.

• Do not overfill (F IG . 31).

• Do not operate G3 without reservoir attached.

• Only use oils with viscosity at least 40 cSt.

a

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splash ing fluid and moving parts, follow the Pressure Relief

Procedure when you stop dispensing and before cleaning, checking, or servicing the equipment.

a. To relieve pressure between the Refill Pump (F) and Auto-Fill Shut Off (B), open the Supply

Hose Pressure Relief Valve (Y) (F

IG

. 30). Pres

sure will be released and excess fluid will drain out of the drain tube (L) and into the lubrication overflow container (W).

Y

L b

F IG . 31

1. Remove fill cap (a).

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

3. Replace fill cap. Hand tighten cap, securely.5

Prime the Pump

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 . 32).

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

W

F IG . 30 b. Close Supply Hose Pressure Relief Valve (Y) when all pressure has been relieved.

6. Disconnect the supply hose (J) from Quick Connect

(V).

332305T 29

Setup

F IG . 32

2. Only run pump until air is no longer dispensed with

the lubricant coming out of element fitting (F IG . 33).

F IG . 33

3. Tighten pump element fitting using two wrenches working in opposite directions (F IG . 32).

30 332305T

Quick Setup Guide

Max Model System - Injector System with Single Sensor Input

Enter Setup

Select

P1

Enter

ON/Backup

Time

MM:SS

Enter

Off

Time

HH:MM

Prelube

Option

OFF

ON

OFF

ON

Enter

Prelube

Delay

MM:SS

System

Runs

According to Settings

Quick Setup Guide

Max Model System - Divider Valve System with Single Sensor Input

Enter Setup

Select

C1

Prox sensor

# of Cycles

(to define run cycle)

C1 01

Enter

ON/Backup

Time

MM:SS

Enter

Off

Time

HH:MM

Prelube

Option

OFF

ON

OFF

ON

Enter

Prelube

Delay

MM:SS

System

Runs

According to Settings

332305T 31

Max Model Setup

Max Model Setup

Control Panel Overview (F IG . 34)

NOTE:

Programming instructions begin on page 33.

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 sec onds.

• 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.

CYCLE / PRESSURE SETUP

• Sets either Cycle (C) or Pressure

(P) Monitoring limits for up to 3 sensors.

• Each sensor is set up and con trolled independently.

• All three LEDs blink if the vent valve output is on.

MACHINE COUNT

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

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

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

LEFT DIRECTION ARROW /

RESET

• In SETUP MODE: moves cursor in display one field to the left.

• In RUN MODE: single press clears warning.

• In RUN MODE: pressing for one second ends run cycle if no warnings.

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

DISPLAY

• A blinking LED under HH, MM, SS or ## identifies type of measure ment 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.

UP and DOWN ARROW

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

SETUP MODE.

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

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 63

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 indicat ing 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 man ual run cycle.

F IG . 34

32 332305T

Max Model Setup

Program the Max Model

Check the Firmware Version

To check the firmware version installed on the pump:

1. Remove power to the pump by disconnecting the power cable from the connection.

2. Reconnect the power cable to the power connec tion.

This creates a power cycle and the firmware ver sion displays on the screen during the first few sec onds of power up. See F IG . 35.

F IG . 35

Power Units With Controllers

By default, units with controllers are set to operate in a timed mode:

FIRMWARE Versions MAX 0506 or

Earlier, DMS 0709 or Earlier:

1 minute of ON time and 8 hours of OFF time.

Later FIRMWARE Versions:

5 minutes of ON time and 1 hour of OFF time.

The unit should be powered up in OFF mode. 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.

Enter 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 follow ing section: Entering a

PIN Code to Access

Setup Mode.

Enter 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 there fore, an option for adding PIN Code authorization is available. The instructions for setting up PIN Code

Authorization are provided in the Advanced Program ming section of this manual. See page 51.

To enter the PIN Code:

1. Press both the UP and

DOWN ARROW buttons for 3 seconds.

332305T 33

Max Model Setup

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 dis play will not blink.

Set 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 programma ble character, the decade, blinks indi cating 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 but tons 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 auto matically moves to the next field, the year number.

3. Use the UP and DOWN arrow but tons to move up and down through the number 0-9 until the number for the current year is dis played 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 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 pro gram 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.

34 332305T

Max Model Setup

2. Press the ENTER button to accept the selection. The cursor automati cally 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 dis played 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 set ting hours and the

LED under the MM lights when setting minutes.

or

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

Program ON Duration

• OFF, C1 (C2, C3) or

P1 (P2, P3) displays, identifying the func tion you are program ming.

• Selection of OFF, C1 (C2, C3) or P1 (P2, P3) desig nates 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, indi cating 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.

332305T 35

Max Model Setup

1. Use UP or DOWN arrow but ton to toggle display between

OFF / C1 / P1 on the display.

2. When C1 is on display, press the

ENTER button to save selec tion 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 num ber 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.

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 39.

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 pre set maximum, activating the (user supplier) pres sure 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.

4. The cycle field is a 2 digit number.

When the correct first numeral of the number displays, press the ENTER but ton 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.

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 sen sor. 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 Program -

ming, A-3 Vent Valve Time, page 51.)

Input Not Used

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

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

C1 / P1 on the display.

36 332305T

Max Model Setup

2. When

OFF is on the dis play, 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.

To determine the Backup Time, Graco recommends the user verify the length of time it takes to complete a typ ical 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.

Program Backup Time

NOTE: When programming a time of less than 10 min utes 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 (min utes) field.

2. Press the ENTER button to lock in the selection. The next MM number field to the right flashes indicating it is ready for programming.

3. Use the UP or DOWN

ARROW button to scroll through numerals 0 to 9 until the desired number appears in the second MM number field.

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

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

5. Repeat steps 1 - 4 to set the SS (seconds) fields.

6. After pressing the ENTER button to set the last SS field, all the programmed ON

Time information is saved.

The G3 automatically switches to the OFF Time

SETUP MODE.

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).

332305T 37

Max Model Setup

• An LED flashes under either MM when pro gramming minutes

OR SS when pro gramming 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 pro gram the ON Time minutes.

The total amount of ON Time can

-

not be 0 or exceed 30 minutes. If a value of 0 or 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.

Program ON Time

NOTE: When programming a time of less than 10 min utes you must program a leading zero in the first num ber field and press the ENTER button to save the zero selection.

1. To set the ON Time use the

UP or DOWN ARROW button to scroll through numerals 0 to 5 until the desired number appears in the first MM (min utes) field.

2. Press the ENTER button to lock in the selection. The next MM number field to the right flashes indicating it is ready for programming.

3. Use the UP or DOWN

ARROW button to scroll through numerals 0 to 9 until the desired number appears in the second MM number field.

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

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

5. Repeat steps 1 - 4 to set the SS (seconds) fields.

6. After pressing the ENTER button to set the last SS field, all the programmed ON

Time information is saved.

The G3 automatically switches to the OFF 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 maxi mum 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 if your model has this feature.

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.

38 332305T

Max Model Setup

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 but ton to change OFF to

RUN or FLT on the display.

• RUN: After backup time expires the pump automati cally goes into an

ON cycle and shows a machine count warning.

• FLT: After backup time expires, the pump automati cally goes into a fault mode.

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).

332305T

• An LED flashes under either HH when pro gramming hours OR

MM when program ming 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 pro gram 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.

Program 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.

39

Max Model Setup

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

6. After pressing the ENTER button to set the last MM field, the OFF Time informa tion is saved.

7. After selecting ON, refer to page 36.

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 pro gramming hours OR

MM when program ming minutes.

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

OR

• The total amount of OFF Time must be at least twice as long as the pro grammed ON Time. If a value less than twice the ON Time is entered, the

RED alarm LED lights and the value must be updated.

If this time does not meet the application needs, contact Graco Customer Support.

Program OFF Time

NOTE: When programming a time of less than 10 hours you must program a leading zero in the first number field and press the ENTER button to save the zero selection.

1. To set the OFF Time use the

UP or DOWN ARROW button to scroll through numerals 0 to 9 until the desired number appears in the first HH (hour) field.

2. Press the ENTER button to lock in the selection. The next HH number field to the right flashes indicating it is ready for programming.

3. Use the UP or DOWN

ARROW button to scroll through numerals 0 to 9 until the desired number appears in the second HH number field.

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

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

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

6. After pressing the ENTER button to set the last MM field, the OFF Time informa tion is saved.

Prelube

The Prelube function determines operation of the pump when power is applied. It can be set to OFF or ON.

OFF (default) - The unit resumes its lubrication cycle at the point it was at when power was removed.

ON - The unit begins a pump cycle.

Set 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 indicat ing you are now in the Prelube setup mode.

40 332305T

Max Model Setup

2. OFF displays. If you want the prelube cycle to begin imme diately, leave this set to OFF.

3. Press the ENTER button to set the selection.

4. If you want to set a prelube delay time, press the DOWN

ARROW button to change OFF to ON on the display.

Prelube Delay

Prelube Delay can be entered to delay the start of the pump’s cycle on power up. If prelube is set to ON, a prelube delay time in MM:SS must be entered. By default, the delay is set to 0 (begin an ON cycle immedi ately).

Delaying the prelube function may be desired if other critical functions or systems of your machine or vehicle are also coming on line during power up.

1. Prelube Delay is set in

MM:SS (minutes and sec onds). To set the time use the

UP or DOWN ARROW button to scroll through numerals 0 to 5 until the desired number appears in the first MM (minutes) field.

The maximum length of time Prelube Delay can be set to is 59:59 (59 minutes:59 seconds).

2. Press the ENTER button to lock in the selection. The next MM number field to the right flashes indicating it is ready for programming.

3. Use the UP or DOWN

ARROW button to scroll through numerals 0 to 9 until the desired number appears in the second MM number field.

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

The next number field to the right flashes and the

LED lights under SS; indicating it is ready to pro gram 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

Download 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 resumes operation.

6. Remove the USB flash drive.

Store Pump Program Settings to the Flash Drive

The pump program settings file is named either:

GRACO/G3Config/g3config.bin (for 0209 and earlier versions) or GRACO/Config/config.bin (for 0706 and later versions): This file cannot be modified. Modifica tion of the file or file name (by anyone but the issuer) 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.

332305T 41

Max Model Setup

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

5. G3 pump resumes operation.

6. After the download is com plete, 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 config uration on the USB drive.

8. When configuration is stored,

“done” is displayed.

9. G3 pump resumes operation.

10. Remove the USB flash drive.

Upload 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 (for 0209 and earlier) or GRACO/Config/config.bin (for 0706 or later).

NOTE: 0707 pumps can take either file setting to upload, but earlier pumps cannot. File names and folders may need to be changed manually when importing settings to an earlier version pump from a later version.

• 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 resumes operation.

6. After the download is com plete, 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.

9. G3 pump resumes operation.

10. Remove the USB flash drive.

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

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

Entering Setup Mode, page 33).

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

34).

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

View 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.

42 332305T

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 down loads are done on the same date, the existing files will be written over.

The folder structure is as follows:

GRACO/{DMS_id}/{download date - YYYYm mDD}/EVENTLOG.CSV

Example: GRACO/00025/20100911/EVENTLOG.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.

DMS ID Number: 0025 (see page 42)

Software Part Number: 16F821

Software Version: 1019

09/29/2010 14:1400

Time Description

332305T 43

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

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 Can celed

Power On

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

The pump powered on.

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 imity switch on a divider valve using the

C3 Cycle Detected sensor input (C1, C2, and/or C3) and has detected one divider valve cycle.

C1 Cycle Com pleted

C2 Cycle Com pleted

C3 Cycle Com pleted

-

-

-

P1 Pressure Com pleted

P2 Pressure Com pleted

P3 Pressure Com pleted

-

-

The system is set up to monitor a prox imity 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.

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

sure switch for an injector system using

Machine Count

Completed

The system is set up to monitor a sen sor 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 initiat ing 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.

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

Venting Completed in an injector system, the system com pleted the vent time.

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

Prelube Delay Com pleted

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

Successful Pin

Code Entry

Firmware Update

Completed

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

The firmware was updated.

Low Power Fault

Pump On

Low Power Warning

Cleared

Low Power Fault

Cleared

The power source does not have enough power to power the pump when it turns on. Replace power source

The voltage of the power source dropped below an acceptable thresh old. The warning was cleared either by user intervention, or by self-correction.

The voltage of the power source dropped below and acceptable thresh old for longer than 15 minutes and the pump failed out. The fault was cleared by the user.

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/{DMS_id}/{download date - YYYYm mDD}/ERRORLOG.CSV

Example: GRACO/00025/20100911/ERRORLOG.CSV.

44 332305T

Operation / Data Log

Sample Error Log

G3 Error Log

DMS ID Number: 00025 (see page 42)

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

Common Error Log entries are listed below.

Software Fault

Low Level Warning

Low Level Fault

C1 Not Detected

C2 Not Detected

C3 Not Detected

P1 Not Detected

P2 Not Detected

P3 Not Detected

System Already Pres surized 1

System Already Pres surized 2

System Already Pres surized 3

-

-

An internal software error occurred. Contact Graco Cus tomer Service.

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

The alarm time in low level warning has elapsed. The unit will not pump until the reser voir is filled and the fault is cleared.

In a divider valve system, the system has not received the programmed number of divider valve cycles for the specified input in the pro grammed backup time.

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

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

Machine Count Sen sor Failure

Motor Overcurrent

High Temperature

Warning

Low Temperature

Warning

The specified number of machine count input activa tions 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 degrada tion in pump life.

Internal temperature of the unit is above the designated oper ating. Check the unit and sys tem to determine that it is functioning correctly. Operat ing outside of the specified temperature range may cause reduced performance and possible unit failure.

Internal temperature of the unit is below the designated oper ating. Check the unit and sys tem to determine that it is functioning correctly. Operat ing 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 con nect and communicate with the pump.

USB Unsupported

Device

The USB flash drive is unsup ported. Use a different flash drive.

-

USB File Not Found The pump program setting file was not found or created cor rectly. Restore the setting file to the flash drive.

USB Folder Naviga tion

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

-

USB Invalid File 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.

332305T 45

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

tional and Technical User Summary, page 53).

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/{DMS_id}/{download date - YYYYm mDD}/FUNCSUM.CSV

Example: GRACO/00025/20100911/FUNCSUM.CSV

Sample Functional Summary

(see page 42)

46 332305T

Common Functional Summary Data entries are listed below.

Number of Cycles

Total Run Hours

The number of lubrication cycles the unit has started.

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

ON/OFF cycle.

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

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 pres sure switch activation in injec tor 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 condi tions related to sensor feed back. This is only applicable if fault retries are used.

-

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

332305T

Operation / Data Log

47

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/{DMS_id}/{download date - YYYYm mDD}/TECHSUM.CSV

Sample Technical Summary

G3 Technical Summary

DMS ID Number: 00025 (see page 42)

Software Part Number:16F821

Software Version: 0205

12/27/201

0

9:50:51

Latest Values

Temp

31C

Voltage

23.877

Example: GRACO/00025/20100911/TECHSUM.CSV

Common Technical Summary Data entries are listed below.

Average Input Board

Voltage (DC)

Peak Input Board Volt age (DC)

The average input voltage mea sured by the internal circuit board.

The peak input voltage measured by the internal circuit board.

Average Motor Current The average motor current mea sured by the unit.

Peak Motor Current The peak motor current mea sured by the unit.

-

Average Internal Tem perature

Peak Internal Tempera ture

Low Internal Tempera ture

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

Start Date Average

Board

12/21/201

0

Voltage

23.877

Factory 9/30/2010 22.804

Peak

Board

Average

Motor

Voltage Current

23.877

0.062

23.877

1.091

Peak

Motor

Current

0.062

0.362

Average

Internal

Temp

30C

33C

Peak

Internal

Temp

35C

42C

Low

Internal

Temp

28C

-10C

48 332305T

Advanced Programming

Advanced Programming

There are 11 Advanced Programming options. The following Table Identifies each option and when it is used.

Advanced

Option

A1

A2

A3

A4

A5

A6

A7

Model

Max

Max

Max

Max

Max

Setting

Lockout

Code (Optional)

Low Level Alarm

Time

Vent Valve Time

Alarm Retry

Active Alarm

DMS ™

Equipped

Models

Max

Functional and

Technical User

Summary Reset

Constant Alarm

Output on Fault

Format/ Description Why Use This?

Secures setup modes with PIN Prevents unauthorized users to adjusting set tings.

MM:SS (minutes:seconds) sets amount of time between Low

Level Warning to Low Level

Fault.

Default = 3 minutes

To accommodate most lubrication situations, a 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.

MM:SS (minutes:seconds) sets amount of time vent valve stays open after Pump ON Mode.

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.

Default = 5 minutes

Sets number of automatic retries after a Cycle or Pressure

Alarm.

Establishes the number of times the unit auto matically retries lubricating after a cycle or pres sure alarm to determine if a temporary or false signal can be cleared.

Default = 0

Changes alarm output behav ior.

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

Default = OFF

Clears the Functional and

Technical User Summaries

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.

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.

Changes alarm output behav ior.

Default = OFF

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

Firmware 6.02 and later

A8

A9

Max

Max and

“08” option

4 Digit Hour Off

Time

Toggle Low Level

Output on Warning or Fault

Changes maximum OFF time.

Default = OFF

Changes Low Level Indication behavior.

Default = OFF

This function changes OFF time from HH:MM to

HHHH. It allows a maximum of 9999 hours of

OFF time.

This function changes the behavior of the low level output in a warning or fault from either steady on or toggling once per second.

332305T 49

Advanced Programming

Firmware 6.04 and later for non-DMS models and 07.07 and later for DMS models.

A10

A11

Max

Max

Low Level Reset

Upon Power ON

Warning OFF through alarm relay

Changes low level fault upon power ON.

Default = OFF

Changes alarm output behav ior.

This function changes the behavior of the low level fault upon power ON.

This function changes the behavior of the alarm output in a warning condition to always OFF.

Default = OFF

Firmware 6.06 and later for non-DMS models and 07.09 and later for DMS models.

A12

A13

Max

Max

Prelube Sequences Changes the number of the

Prelube sequences.

MM:SS Off Time

Default = 0001

Changes the OFF time pro gramming from HH:MM to

MM:SS

Default = OFF

This function changes the behavior of the pre lube function to add more lubrication sequences upon pump start up.

This function changes the programming of the

OFF time.

Entering a PIN Code for the First Time

A1 - Set Up PIN Code

A PIN Code can be programmed into the G3 to protect the settings from inadvertently being changed by unau thorized users.

1. Press the UP ARROW button for 10 seconds.

5. Press the ENTER button to set the number. The cursor automatically moves to the next number field.

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

7. Press the ENTER button to save the

PIN Code and exit Advanced Setup.

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.

Enter Advanced Setup

Press the UP ARROW button for 10 sec onds.

If the G3 was previously set up to require a

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

1. The cursor is automatically positioned to enter the first character of the PIN Code.

Use the UP and DOWN

ARROW buttons to move up and down through the numbers 0-9 until the first number in the PIN code is displayed in the field.

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

50 332305T

Advanced Programming

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.

Select Advanced Setup Options

1. Press the UP or DOWN

ARROW button to move up or down through Advanced

Options A1 - A13.

2. Press the ENTER button to set the selection.

A2 - Low Level Alarm Time

Pump ON mode only.

Programs the amount of time in MM: SS (minutes and seconds) the pump can run between a Low Level Warn ing and a Low Level Fault to help protect unit from run ning dry.

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

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

F IG . 36

NOTE: When programming a time of less than 10 min utes you must program a leading zero in the first num ber field and press the ENTER button to save the zero selection.

1. To set the time use the UP or

DOWN ARROW button to scroll through numerals 0 to

9 until the desired number appears in the first MM (min utes) field.

2. Press the ENTER button to lock in the selection. The next MM number field to the right flashes indicating it is ready for programming.

3. Use the UP or DOWN

ARROW button to scroll through numerals 0 to 9 until the desired number appears in the second MM number field.

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

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

5. Repeat steps 1 - 4 to set the SS (seconds) fields.

6. After pressing the ENTER button to set the last SS field, all the programmed ON

Time information is saved.

Unit exits Advanced Programming.

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 40). 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.

332305T 51

Advanced Programming

To set Vent Valve Time:

NOTE:

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

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

7. After pressing the ENTER button to set the last seconds field, all the pro grammed 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 num ber field and press the ENTER button to save the zero selection.

1. To set the Time use the UP or DOWN ARROW but ton 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; indi cating it is ready to program the Sec onds fields.

A4 - Alarm Retry

Programs the number of times G3 will automatically retry running a lubrication cycle after a cycle or pres sure alarm activates. The default setting is 0. For assis tance 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 . 37

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

52 332305T

0-9.

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.

A5 - 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 - Clear 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 . 38

1. The default OFF dis plays.

2. Press the UP or DOWN

ARROW button to change

OFF to ON on the display to activate alarm condition.

332305T

F IG . 39

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 but ton. “Reset” displays.

The summary data is cleared.

5. Press the RESET or

ENTER button to exit.

53

Advanced Programming

A7- 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

A8 - 4 Digit Hour OFF Time

Changes the OFF time from HH:MM to HHHH. Allows for a maximum of 9999 hours of OFF time.

OFF LED illuminates.

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 . 40

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.

F IG . 41

1. The default OFF dis plays.

2. Press the UP or DOWN

ARROW button to change

OFF to ON on the display to activate alarm condition.

3. Press the ENTER button to exit

Advanced Programming.

54 332305T

Advanced Programming

A9 - Toggle Low Level Output on Low Level

Warning or Fault

This function changes the behavior of the low level out put in a warning or fault from either steady on (default) or toggling once every second.

Low Level and Warning LEDs Illuminate

Models with Firmware 6.03 and later. DMS Models with

Firmware 7.07 and later.

A10 - Low Level Reset Upon Power On.

This function changes the behavior of the low level upon pump power on. When A10 is on, a low level fault clears when the pump power is cycled. The pump will revolve 5 revolutions, checking to see if the low level condition is still present. If not, it will self clear and con tinue. If a low level condition exists during the 5 revolu tions, it will go into a low level fault.

Low Level ON LED illuminates (F IG . 43).

F IG . 42

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.

332305T

F IG . 43

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

2. Press the UP or DOWN

ARROW button to change

OFF to ON on the display to change the low level reset upon power on.

55

Advanced Programming

3. Press the ENTER button.

A11- Warning Off Through Alarm Relay

This function changes the behavior of the alarm output in a warning condition to always off.

Fault and Warning LEDs Illuminate

Models with Firmware 6.06 and later for non-DMS models.

Models with Firmware 7.09 and later for DMS models

A12 - Prelube Sequences

This function changes the behavior of the prelube func tion to add more lubrication sequences upon pump start up. While running multiple sequences, after the ini tial sequence, PL:xx will be displayed showing how many sequences are left.

Note: if pump has option “08” and using a pressure switch with multiple sequences, a vent delay time must be programmed under Advanced Programming Option

A3.

Prelube LED illuminates (F

IG

. 43)

F IG . 44

1. The default OFF is displayed. The alarm output will turn on during a warning condition.

2. Press the UP or DOWN

ARROW to change OFF to

ON on the display to change the alarm output to be off during a warning condition.

3. Press the ENTER button to exit

Advanced Programming.

56

F IG . 45

1. The default 0001 is displayed.

When Prelube is on, it will run one sequence.

2. Press the UP or DOWN

ARROW button until desired number of prelube sequences displays.

332305T

Advanced Programming

NOTE: When prelube is on, and the pump is pow ered-up, the pump will run this amount of lubrica tion ON sequences.

3. Press the ENTER button to exit

Advanced Programming after the last digit of the prelube sequence is dis played.

A13- MM:SS OFF Time

This function changes the programming of the OFF

Time.

OFF and Warning LEDs Illuminate

332305T

F IG . 46

1. The default OFF is displayed.

Off/Backup time in setup mode is displayed in HH:MM

(Hours/Minutes).

2. Press the UP or DOWN ARROW to change OFF to ON on the dis play. The OFF/Backup Time in setup mode will be displayed in

MM:SS (Minutes/Seconds).

3. Press the ENTER button to exit

Advanced Programming.

57

Run Mode

Run Mode

Time Control

After setup is complete, the G3 automatically begins to run the OFF Time sequence (F IG . 47).

• 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 . 47 shows an OFF Time of 1 hour and 32 minutes before the lubrication cycle begins.

HH MM SS ##

!

ON

MM : SS

OFF

HH : MM

C

P

1

C

P

2

C

C

P

3 P

1 2 3

HH MM SS ##

!

ON

MM : SS

C

P

1

C

P

2

C

C

P

3 P

OFF

HH : MM

1 2 3

F IG . 47

• 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 .

48).

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

• The example shown in F IG . 48 shows an ON Time of 8 minutes and 42 seconds before the lubrication cycle ends.

F IG . 48

• When the ON Time count reaches zero, the pump shuts off again and the system again runs OFF

Time cycle and the OFF Time LED is now again illu minated (F IG . 47).

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.

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 58).

58 332305T

Run Mode

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

.

49).

The example shown in F

IG

. 49 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

. 50 and F

IG

. 51).

• 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

. 50 shows sensor P1 with a pressure switch that has been triggered.

F

IG

. 51 (page 60) shows sensor P2 with a pres sure switch that has NOT been triggered.

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 . 49

F IG . 50

332305T 59

Run Mode

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 . 51

60

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

. 52 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 . 52

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.

332305T

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

. 53).

• The display indicates the number of machine counts remaining.

The example shown in F

IG

. 53 shows the remaining number of machine counts is 0045.

HH MM SS ##

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

. 54).

• The display alternates between machine counts remaining and backup time.

The example shown in F

IG

. 54 shows 4 hours and 17 minutes remaining until a fault or lubri cation mode (pump ON) 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 ##

!

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

C

P

3 P

1 2 3

F IG . 53

F IG . 54

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 58).

• The LED next to the clock in the OFF field illumi nates.

• The display shows the time remaining until the lubrication cycle begins.

332305T 61

Run Mode

Additional Controls

Venting

In Max models a Vent Time can be set using the

Advanced Programming mode (page 51). This is typi

cally done in a Pressure Based System (P1) to allow injectors to reset.

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

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

• The pump will not run while in Venting mode.

• If Machine Count is set, the display will alter nate between machine counts remaining and backup While unit is venting, VEnt will display and alternate with Machine Count and the

Backup Time or the OFF Time.

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

Mode Controls, page 58).

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 and after the Prelube Delay time runs out, the lubrication cycle begins.

• The LED next to the clock in the OFF field is illuminated (F

IG

. 56).

• The Prelube LED lights (F

IG

. 56).

• The display shows time remaining until lubrica tion cycle begins. The example shown in F

IG

.

56 shows 8 minutes and 14 seconds left until a lubrication cycle begins.

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

P

3

C

P

1 2 3

C

P

1

C

P

2

C

P

3

C

P

1 2 3

F

IG

. 55

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.

62

F

IG

. 56

Manual Run Cycle

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

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

332305T

Alarms: Firmware Versions 6.01 and Below

Alarms: Firmware Versions 6.01 and Below

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 addi tional lubricant needs to be added.

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

Solution

Add lubricant to reservoir.

After lubricant is added, press the

RESET but ton to clear the warning.

C

P

1

C

2

P

C

C

P

3 P

1 2 3

332305T 63

Alarms: Firmware Versions 6.01 and Below

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 addi tional lubricant needs to be added.

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

-

Add lubricant to reservoir.

After lubri cant is

added press and hold the

RESET button to clear fault.

If repriming pump is required, the low level alarm time should be decreased. See A-2:

Advanced Programming,

Low Level Alarm Time

page 51.

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

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

Unit will continue to oper ate for the number of lubri cation cycles set by the warning retry parameter

(see Advanced Program -

ming, page 49).

Press the

RESET but ton to clear warning.

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

64 332305T

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: Firmware Versions 6.01 and Below

In pressure mode indi cates that unit is over pres surized or a lubrication cycle was not completed in the user-defined amount of time.

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

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

Press and hold the

RESET but ton 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 deter mine if the machine sen sor is operating properly.

Press and hold the

RESET but ton to clear fault.

332305T 65

Alarms: Firmware Versions 6.01 and Below

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 Cur rent Warn ing 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 cur rent is above the recom mended operating maximum value. Contin ued use at excessive motor currents could reduce life or cause per manent damage.

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

Examine pump to ensure that it is rotating properly.

If necessary, contact

Graco Customer Service.

66 332305T

Tempera ture 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: Firmware Versions 6.01 and Below

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

Use of the unit outside of the recommended tem perature range could cause degraded system performance and possible damage.

Ensure the unit is used in the correct operating environment for the spe cific temperature: -13° F to 158° F (-25° C to

70°C).

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 75) for error num

bers and fault descrip tions.

332305T 67

Alarms: Firmware Versions 6.02 and Above

Alarms: Firmware Versions 6.02 and Above

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. An error message will display and flash every 2 seconds for an alarm, temperature or current warning and every 10 seconds for all other types of warnings.

• Faults will not automatically clear. Warnings will clear after a set time, if condition was fixed.

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

• To clear a warning instantly 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

C

P

1

C

2

P

C

C

P

3 P

1 2 3

!

What it Indicates

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

Solution

Add lubricant to reservoir.

After lubricant is added, press the

RESET but ton to clear the warning.

Unit continues to operate as normal for a limited period of time until a low level alarm is triggered or until the reservoir is filled and 30 seconds has passed at which time the warning will self-clear.

68 332305T

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 Warn ing

HH MM SS ##

!

ON

MM : SS

OFF

HH : MM

C

P

1

C

P

2

C

C

P

3 P

1 2 3

Alarms: Firmware Versions 6.02 and Above

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

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

-

Add lubricant to reservoir.

After lubri cant is

added press and hold the

RESET button to clear fault.

If repriming pump is required, the low level alarm time should be decreased. See A-2:

Advanced Programming,

Low Level Alarm Time

page 51.

A lubrication cycle was not completed in the user-defined amount of time.

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

Unit will continue to oper ate for the number of lubri cation cycles set by the warning retry parameter

(see Advanced Program -

ming, page 49).

Press the

RESET but ton to clear warning.

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

332305T 69

Alarms: Firmware Versions 6.02 and Above

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

Cycle Fault

HH MM SS ##

!

ON

MM : SS

OFF

HH : MM

C

P

1

C

P

2

C

C

P

3 P

1 2 3

System fails to relieve pressure in the user-defined amount of time.

Unit will continue to oper ate for the number of lubri cation cycles set by the warning retry parameter

(see Advanced Program -

ming, page 49).

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

Press the

RESET but ton to clear warning.

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

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

LED corresponding to the affected sensor input blinks.

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

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

Press and hold the

RESET but ton to clear fault.

70 332305T

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

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: Firmware Versions 6.02 and Above

In pressure mode indi cates that unit is over pres surized or a lubrication cycle was not completed in the user-defined amount of time.

LED corresponding to the affected sensor input blinks.

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

Press and hold the

RESET but ton to clear fault.

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

The unit has not received the correct number of machine counts in the user defined Backup Time.

Examine system to deter mine if the machine sen sor is operating properly.

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

Press and hold the

RESET but ton to clear warning.

332305T 71

Alarms: Firmware Versions 6.02 and Above

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

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

Backup Time.

Examine system to deter mine if the machine sen sor is operating properly.

Press and hold the

RESET but ton to clear fault.

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.

72 332305T

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

Alarms: Firmware Versions 6.02 and Above

The measured motor cur rent is above the recom mended operating maximum value. Contin ued use at excessive motor currents could reduce life or cause per manent damage.

Examine system to make sure it is operating cor rectly. A blocked line motor current

could create excessive

Examine pump to ensure that it is rotating properly.

Warning will self-clear any time after 15 seconds On

Time start if the system correction is made.

If necessary, contact

Graco Customer Service.

Tempera ture 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 internal temperature of the unit is out of its recom mended operating range.

Use of the unit outside of the recommended tem perature range could cause degraded system performance and possible damage.

Ensure the unit is used in the correct operating environment for the spe cific temperature: -13° F to 158° F (-25° C to

70°C).

If necessary contact

Graco Customer Service.

332305T 73

Alarms: Firmware Versions 6.02 and Above

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 75) for error num

bers and fault descrip tions.

74 332305T

Fault/Warning Scenarios for Firmware Versions 6.06 and Later for Non-DMS Models and 7.09 and later for DMS Models

Fault/Warning Scenarios for Firmware Versions 6.06 and Later for Non-DMS Models and 7.09 and later for

DMS Models

Alarm Type

Low Power

Warning

What it Looks Like

Low Power

Fault

HH MM SS ##

ON

MM : SS

OFF

HH : MM

C

P

1

C

P

2

C

C

P

3 P

1 2 3

HH MM SS ##

!

!

What it Indicates

If there is a voltage drop at the power source during operation, the pump will go into a low power warning condition.

Solution

Check voltage and avail able current output at the power source of the pump.

The unit will continue to operate for a total of 15 minutes before going into a Low Power Fault.

Also if the pump power cycles on power up for a minimum of 3 times, the pump will display a low power warning.

If the warning condition clears itself, the warning is cleared and the unit con tinues operation.

There is a low voltage con dition at the power source.

Check voltage and avail able current output at the power source of the pump.

Press and hold the

RESET button to clear fault.

ON

MM : SS

OFF

HH : MM

C

P

1

C

P

2

C

C

P

3 P

1 2 3

332305T 75

Recycling and Disposal

Recycling and Disposal

End of Product Life

At the end of the product’s useful life, dismantle and recycle it in a responsible manner.

• Perform the Pressure Relief Procedure .

• Drain and dispose of fluids according to applicable regulations. Refer to the material manufacturer’s

Safety Data Sheet.

• Remove motors, batteries, circuit boards, LCDs

(liquid crystal displays), and other electronic components. Recycle according to applicable regulations.

• Do not dispose of batteries or electronic components with household or commercial waste.

• Deliver remaining product to a recycling facility.

76 332305T

Troubleshooting

Troubleshooting

Follow the Pressure Relief on page 23 before checking

or repairing the equipment.

only)

Problem

Unit does not power on

Unit does not power on (DC models

Cause

Incorrect/loose wiring

Tripped external fuse due to internal component failure

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

Solution

Refer to

Installation instructions, page 13.

Contact Graco Customer Service.

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

Replace fuse.

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

Tripped internal power supply fuse due to power supply failure

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

-

Time entered was misinterpreted as

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

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

Dim display, unit is not operating

Failed motor

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 lubri cant

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

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

Contact Graco Customer Service.

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

Verify the unit was programmed as intended, referencing programming instructions. Note the dot designa tion 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

Ensure vent hole is not plugged.

If problem persists, contact Graco

Customer Service or your local

Graco distributor for assistance.

Replace unit.

Add grease following Loading

Grease instructions, page 24. Ensure

air is purged.

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

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

-

332305T 77

Troubleshooting

Problem

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

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

Cause

The ON Time was not entered cor rectly

Vent valve time needs to be config ured

Display acts erratically

USB Error 00

USB Error 07

USB Error 11

USB Error 12

USB Error 13

Solution

Refer to programming ON Time,

pages 35 and 58.

Refer to Advanced Programming to

set ON Time, page 49.

Faulty cycle/pressure wiring connec tion to unit

Flash drive was removed during operation

-

Flash drive unable to mount (initial ize)

• Unplug the flash drive and re-install.

• Cycle power and re-install the flash drive.

• Retry using a different flash drive.

• Verify format is FAT32 file sys tem. If not, may need to reformat flash drive or find a different drive that has this file system.

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

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

Flash Drive, page 41 for instructions.

Pump program settings directory not found.

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 opera tion.

Bad pump program settings file

Settings file is from different firm ware version

-

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

Flash Drive, page 41 for instructions.

The pump programs settings file is corrupt. Restore file to the flash drive. See Storing Pump Program

Settings to the Flash Drive, page 41

for instructions.

Program pump manually or recreate settings file from a pump that has the same firmware version. See Storing

Pump Program Settings to the Flash

Drive, page 41 for instructions.

78 332305T

Problem

All other USB errors

Cause

Troubleshooting

Solution

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

• Unplug the flash drive and rein stall.

• 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 Ser vice.

332305T 79

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.

80 332305T

Parts - 2 Liter Models

Parts - 2 Liter Models

332305T 81

Parts - 4 Liter and Larger Models

Parts - 4 Liter and Larger Models

82 332305T

Parts

Parts

1

3

4

Ref Part Description

BASE, three pump housing

25V211 COVER, bottom, with seal

Qty

1

1

133767 SCREW, mach, torx pan hd, o-ring 9

12 127079 RECT-RING, included in Kit

13 132524 O-RING, included in Kit 571042,

14 278144 PLATE, ricer

15 120822 BEARING, ball

16

17

PADDLE, stirring, 2 Liter models without follower plate, included in

Kit 571044

PADDLE, stirring, 4 Liter models and larger without follower plate, included in kit 571046

PADDLE, stirring, 2 Liter models with follower plate, included in Kit

571045

PADDLE, stirring, 4Liter models and larger with follower plate, included in Kit 571047

PUMP, element, included in Kit

571041

18 16F368 SPACER, stroke adjust, included

21 278145 PLUG, pump, 3/4-16

23 ❖ 279043 PADDLE, low level

27 123025 SCREW, M6

30

‡ ★

258697 BOARD, circuit, Max, models

‡ ★ models

31 119228 SCREW, machine, flat head

33

16A579 LABEL, safety

34 16A073 LABEL, overlay

1

1

1

1

1

1

1

2

1

1

1

1

1

2

2

1

1

1

Ref

35

36

Part Description

WIPER, stirring, models without follower plate, included in Kits

571044, 571045, 571046, and

571047

1

WIPER, stirring, models with fol lower plate, included in Kit 571045 1

LABEL, brand

37 123741 FITTING, Zerk, grease

Qty

1

1

40a 24E984 RESERVOIR, 2 liter, grease, 1

1

1

1

40c 17F484 RESERVOIR, 4 Liter, G3 AFSO

41

1

278139 SEAL, follower plate, 2 liter models 1

16F472 SEAL, follower plate, 4 liter models 2

42

43

44

PLATE, follower

ROD, follower plate

SPRING, compression

45† 24D838 BAFFLE, low level, 2 liter models 1

† 24E246 BAFFLE, low level, 4 liter models 1

1

1

1

24F836 BAFFLE, low level, 8 liter models 1

24F923 BAFFLE, low level, 12 liter models 1

24F924 BAFFLE, low level, 16 liter models 1

56 127144 SEAL, oval

57 117156 BEARING, sleeve

58 ▲ 196548 LABEL, electric shock (not shown) 1

1

1

332305T 83

Parts

88

89

90

91

82

83

84

85

87

Ref Part Description Qty

RESERVOIR, mid-section kit, with o-ring

(see quantity by size / model below)

8 Liter models 1

61 25C764

12 Liter models 2

16 Liter models

62 574002 ADAPTER, reservoir

3

1

66 126417 NUT, oil

67 24N806 FLOAT, oil

74 SPRING, plate, valve, reset

75 ▲ 15H108 LABEL, safety, pinch

81 VALVE, AFSO

1

1

1

1

1

BOLT, mounting

PACKING, o-ring

PACKING, o-ring

SEAL, upper, reservoir

SEAL, lower, reservoir

SPACER, seal, base

PLATE, valve

TUBE, center fill

WASHER, plain

1

1

1

1

1

1

1

1

1

Ref

92

200

201

202

Part Description

PIN, alignment

16U790 CABLE, DIN, bare)

▲ Replacement Danger and Warning labels, tags and cards are available at no cost.

Also order Ref 27, Part No. 123025

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

No. 16A073

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

1

1

Qty

1

1

1

1

1

1

1

1

84 332305T

Parts

Pressure Relief Valves

Important Information regarding Pressure Relief

Valve 16C807.

Pressure Relief Valve 16C807 can only be used on the G3, G1, or G-Mini Pumps.

It is not intended for use with any other products.

The pressure relief valve uses a pressure adjustment screw (a) to set the pressure release point. It is not intended as a way to relieve pressure during normal operation, but as a protective measure in the event there is an unintended pressure increase in the system. Do not use this pres sure relief valve a means of relieving pressure in day-to-day, normal cycle operation.

The pressure adjustment screw may require periodic adjust ments. 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.

NOTE: Each pressure relief valve requires banjo kit p/n

571058. (Except 16C807 because the banjo is already included in kit 571028).

Part

16C807 ◆

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

Qty

1

1

1

1

1

1

1

1

Fuses

Part Description

571039 FUSE, 7.5 A for 12 volt DC

571040 FUSE, 4 A for 24 volt DC

Installation and Repair Kits

Kit No.

Description

571026 KIT, output union, 3 pump

571063 KIT, output union, 2 pump pressure relief valve 16C807

571030 KIT, remote manual run, 12 volt DC

571031 KIT, remote manual run, 24 volt DC

571036 KIT, cover with “G” label

Qty

1

1

Manual

Number

3A0523

NA

3A0533

571069

571044

571045

571046

571047

KIT, repair, 2 liter reservoir, for models with follower plate, includes Ref 12, 13,

36, 40

KIT, replacement, paddle, 2 liter, for mod els without follower plate, includes Ref 13,

16, 35, 57

KIT, replacement, paddle, 2 liter, for mod els 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 mod els with follower plate, includes Ref 13, 16,

35, 57

571058 KIT, output adapter, NPT

571070 KIT, output, adapter, BSPP

571060 KIT, fill, zerk, leak proof

3A0534

3A0535

3A0522

NA

571183 KIT, repair, reservoir, grease, 4 liter mod

127685 RING, fixing for CPC connector

-

16G022 CAP, filler

3A0525

3A0528

3A0534

NA

1

332305T 85

Parts

Reservoir Conversion Kits

Kit No.

Description

Manual

Number

571155 KIT, reservoir conversion, 4 Liter

571156 KIT, reservoir conversion, 8 Liter

571157 KIT, reservoir conversion, 12 Liter

571158 KIT, reservoir conversion, 16 Liter

3A1260

571299 KIT, reservoir conversion, 4L Top Fill 3A8295

571286 KIT, reservoir conversion, 4 L AFSO

571287 KIT, reservoir conversion, 8 L AFSO

571288 KIT, reservoir conversion, 12 L AFSO

571289 KIT, reservoir conversion, 16 L AFSO

3A5051

Dimensions

Model

2L

4L

4L Top Fill

8L

8L Top Fill

12L

12L Top Fill

16L

16L Top Fill

Inches

Height

13.25

14.50

15.50

18.50

19.50

23.00

24.00

27.50

28.50

cm

33.65

36.83

39.37

47.00

49.53

58.42

60.96

69.85

72.39

Inches

8.00

9.25

9.25

9.25

9.25

9.25

9.25

9.25

9.25

Width cm

20.32

23.50

23.50

23.50

23.50

23.50

23.50

23.50

23.50

Inches

9.00

10.00

10.00

10.00

10.00

10.00

10.00

10.00

10.00

Depth cm

22.86

25.40

25.40

25.40

25.40

25.40

25.40

25.40

25.40

86 332305T

Mounting Pattern

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

Option 1

0.

3 67inch

9.

3 mm

7.087 inch

1 80.0 mm

2 x Ø 0.

3 66 inch

9.

3 mm

1 .

1 80 inch

3 0.0 mm

3 .

2 68 inch

8 3 .0 mm

Parts

Option 2

2 x Ø 0.

3 66 inch

9.

3 mm

0.7

22 inch

1 8.

3 mm

3 .544 inch

90.0 mm

6.

3 78 inch

1 6 2 .0 mm

0.708 inch

1 8.0 mm

3 .740 inch

95.0 mm

3 .

1 89 inch

8 1 .0 mm

F IG . 57

332305T 87

Technical Specifications

Technical Specifications

G3 Max Automatic Lubrication Pump

Pump output pressure

Fill inlet pressure

Power

100 - 240 VAC

US

5100 psi

5000 psi

12 VDC

24 VDC

Outputs - Alarm Relay

Rated Load

Metric

35.1 MPa, 351.6 bar

34.4 MPa, 344.7 bar

88-264 VAC; 0.8 A current, 90 VA Power, 47/63 Hz, Single phase, inrush/locked rotor max 40 A (1ms)

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

18-30 VDC; 2.5 A current, 60 W, inrush/locked rotor 6 A

Max Operation Voltage

Max Operating Current

Max Switching Capacity

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 VAC

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

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

Resistive: 50 VA, 60 W

Inductive: 25 VA, 30 W

Resistive: 10 µA, 10m VDC

Inductive: 10 µA, 10m VDC

Min Permissible Load

Outputs - Vent Valve

Required Switch Type

Sensor Voltage

100 - 240 VAC

12 VDC

Normally closed

24 VDC

Input Voltage

Input Voltage

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

Fluid

Grease Models

Oil Models

22 mA @ 24 VDC

11 mA @12 VDC

22 mA @ 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)

Grease NLGI #000 - #2

At least 40 cSt. oil

88 332305T

Technical Specifications

G3 Max Automatic Lubrication Pump

US Metric

Pumps

Pump Output

Pump Outlet

Reservoir Size

IP Rating

Sensor Inputs

Up to 3

0.12 in.

0.18 in.

0.25 in.

3

3 (3 cm

3

(2 cm 3

(4 cm

3

3

) / minute per outlet - 2 spacers

) / minute per outlet - 1 spacer

) / 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 to 158°F -40°C to 70°C Ambient Temperatures

Noise (dBa)

Maximum sound pressure

Materials of Construction

Wetted Parts

<70dBa nylon 6/6 (PA), amorphous polyamide, zinc plated steel, carbon steel, alloy steel, stainless steel, nitrile rubber

(buna-N), bronze, nickel plated alnico, chemically lubricated acetal, aluminum, PTFE

All trademarks or registered trademarks are the property of their respective owners.

Pump Maximum Weight (lbs)

Model

2L

4L

8L

12L

16L

With follower plate

12.4

15.3

16.8

18.4

19.9

Without follower plate With auto-fill shut off

11.4

13.1

14.6

16.1

17.6

N/A

17.9

19.7

21.6

23.4

California Proposition 65

CALIFORNIA RESIDENTS

WARNING: Cancer and reproductive harm – www.P65warnings.ca.gov.

332305T 89

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

.

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

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.

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

Revision T , May 2023

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