Graco 332298B User Manual

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Instructions

Conforms to ANSI/UL 73 Certified to CAN/CSA Std. 22.2 No 68-09

3132066

G3 Pro Automatic

332298B

Lubrication Pump

For dispensing of NLGI Grades #000 to #2 greases and oil with at least 40cSt. For Professional Use Only.

Not approved for use in explosive atmospheres or hazardous locations.

Part Nos., page 3

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

Important Safety Instructions Read all warnings and instructions in this

manual. Save these instructions.

Table of Contents

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

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

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

8 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

12 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 3

16 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Understanding the Model Number . . . . . . . . . . . 4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 8

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2 332298B

96G078 G3-G-ACPR-160L00-0D000000 96G167 G3-G-24PR-160L05-00C00000

Model Numbers

332298B 3

Part / Model Numbers

Understanding the Model Number

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

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

G3 -G - PR 0 00 0

Code Sample: a a b b - c c d e f f - g h i j k m n p

G3 - G = Identifies pump as being a G3; G = Grease G3 - A = Identifies pump as being a G3; A = Oil

Code aa: Power Source

• 12 = 12 Volts DC

• 24 = 24 Volts DC

• AC = 100 - 240 Volts AC

Code bb: Operation Control

• PR = Pro (Timer) Control

Code cc: Reservoir Capacity (Liters)

• 2L = 2 Liters

• 4L = 4 Liters

• 8L = 8 Liters

• 12 = 12 Liters

• 16 = 16 Liters

Code d: Follower Plate Installed

• F = Follower Plate Installed

• 0 = No Follower Plate

Code e: Low Level Option

• L = Low Level with Controller

• 0 = No Low Level monitoring

Code ff: Options

• 00 = No Options

• 05 = 5 Pin CPC power cable

Code g, h, i, j, k, m, n, p NOTE: Codes g - p relate to a specific location on the

G3 pump. See F

•C = CPC

•D = DIN

• R = Remote Manual Run

• 0 = Not populated

IG. 1 for these locations.

FIG. 1

4 332298B

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 at main switch before disconnecting any cables and before servicing or installing equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

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.

332298B 5

Warnings

WARNING

PRESSURIZED EQUIPMENT HAZARD

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

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

• Follow Pressure Relief Procedure in this manual before servicing.

PLASTIC PARTS CLEANING SOLVENT HAZARD

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

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

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

MOVING PARTS HAZARD

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

• Keep clear of moving parts.

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

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer

6 332298B

Installation

G3-G-24PR-2LFL00-R0C00000

Grease Models with Follower Plate

96GXXX

Oil Models

Grease Models

Installation

Grounding

The equipment must be grounded. Grounding reduces the risk of electric shock by providing an escape wire for the electrical current in the event of malfunction or breakdown. This product is equipped with a cord having an equipment grounding conductor. The wire with insulation having an outer surface that is green with or without yellow stripes is the grounding wire.

Component Identification

FIG. 2:

Key:

A Reservoir B Adjustable Pump Element (1 included. Can accommodate

C Pressure Relief Valve (Not included / required for each

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

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

332298B 7

3 total)

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

output volume per stroke) (also see F

Available from Graco. See Parts, page 38.)

H Control Panel I Power / Sensor Panel (both sides; only one side shown) J Part Number / Model Number example only shown, (see

pages 4, Understanding the Model Number, for details) K Power Cord (DIN shown) L Follower Plate (grease models only / not available on all

M Vent Hole for Follower Plate (grease models only / not

IG. 12, page 19)

N Fill cap (oil models only)

grease models)

available on all grease models)

Installation

Typical Installation

Divider Installations

A Connected to fuse / power B Pressure relief valve (Not included/required for each

outlet - user supplied. See Parts, page 38)

C - Cycle indicator sensor cable to external controller

(Divider Installations)

- Pressure switch cable to external controller (Injector Installations)

D - Series progressive divider valves (Divider Installations)

- Injectors (Injector Installations) E To lube points F - Proximity Switch (Divider Installations)

- Pressure switch (Injector Installations)

8 332298B

Installation

Choosing an Installation Location

AUTOMATIC SYSTEM ACTIVATION HAZARD

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

This device has an automatic timer that activates the pump lubrication system when power is connected or when exiting the programming function. Before you install or remove the lubrication pump from the system, disconnect and isolate all power supplies and relieve all pressure.

• Select a location that will adequately support the weight of the G3 Pump and lubricant, as well as all plumbing and electrical connections.

• Refer to the two mounting hole layouts provided in the Mounting Pattern section of this manual, page 41.

NOTE: The two mounting hole layouts provided in the Technical Data section show the only correct installation patterns to use for mounting the G3. No other installation configurations should be used.

• Use designated mounting holes and provided configurations only.

• Always mount the G3 oil models upright.

• If the G3 grease model is going to be operated in a tilted or inverted position for any period of time, you must use a model that includes a follower plate, otherwise the G3 must be mounted upright. Refer to your model number to confirm if a follower plate was installed on your pump. See page 4, Understanding the Model Number to identify this character in your model number.

• Use the three fasteners (included) to secure the G3 to the mounting surface.

• Some installations may require an additional reservoir support bracket. Consult your Graco distributor for assistance with this installation.

332298B 9

Installation

System Configuration and Wiring

Fuses

Improper installation of the grounding conductor may result in a risk of electric shock. This product must be installed by a qualified electrician in compliance with all state and local codes and regulations.

If the product is permanently connected:

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

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

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

• It must be rated for the product electrical specifications.

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

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

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

NOTICE

Fuses (user supplied) are required on all DC models. To avoid equipment damage:

• Never operate G3 Pump DC models without a fuse installed.

• A fuse of the correct voltage must be installed in line with the power entry to the system.

Fuse Kits are available from Graco. The following Table identifies the correct fuse to use for your input voltage and the corresponding Graco Kit number.

Input Voltage

12 VDC 24 VDC

Fuse Value

7.5 A 4 A

Graco Kit No.

571039 571040

Recommendations for Using Pump in Harsh Environments

• Use pump with CPC style power cable.

• If using a DIN style power or alarm harness with a right angle mating connector, make sure the connector does not exit the unit in the UP direction.

• Use a corrosion preventative electrical grease on all contacts.

10 332298B

Installation

Remote Illumination Response

The following tables include graphical representations of the connector as it appears on the unit, a pin-out associated with the connector and a typical installation wiring diagram. An internal representative wiring diagram is included where it is deemed useful.

Wire colors provided on these pages only refer to the power cable provided by Graco with this product.

Standard Remote Illumination

(via 5 wire CPC power cable)

Unit in OFF Mode Off Off Unit in ON Mode On Green Warning Condition Toggles On and Off once per second Yellow Fault Condition Toggles On and Off once per second Red

Tri-Color Remote Illumination

(via illuminated manual run input)

Wiring and Installation Diagrams

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

Diagram Symbol Page #

Power DIN AC 12

Power DIN DC 13

Power CPC DC 15

Illuminated Manual Run Input

Kits: 571030, 571031, 571032, 571033

332298B 11

Installation

(4)

(2)

(1)

Example Wiring Diagram

Connector on Housing

Connector on Cable

(4)

(1)

(3)

(2)

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

Pin and Related Wire Color (FIG. 3)

Pin Pin Name Color

1 Line Black 2 NEUTRAL White 3 Not Used Not Used 4GROUND Green

FIG. 3

12 332298B

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

Ignition Switch

Fuse

Example Wiring Diagram

Connector on Housing

12V-pump - 7.5A - Graco kit #571039 24V pump - 4A - Graco kit #571040

(4)

(2)

(1)

Connector on Cable

(4)

(1)

(3)

(2)

NOTICE

Be sure when power is applied that stirring paddle rotates clockwise (when viewed from the top). If it is wired incorrectly paddle could rotate counter-clockwise which will damage the pump’s internal components. If this happens, stop the pump immediately and wire unit correctly.

Pin and Related Wire Color (FIG. 4)

Installation

Pin Pin Name Color

1-VDC Black 2+VDC White 3 Not used Not used 4 Not used Green

FIG. 4

332298B 13

Installation

(1)

(2)

(3)

(4)

(5)

(6)

(7)

Example Wiring Diagram

Connector on Housing

Connector on Cable

Ignition Switch

Fuse

12V-pump - 7.5A - Graco kit #571039 24V pump - 4A - Graco kit #571040

(1)

(3)

(2)

(7)

(6)

(5)

(4)

Power CPC DC - 15 foot: Part No. 126217

Pin and Related Wire Color (FIG. 5)

Pin Pin Name Color

1 Not Used Not Used 2-VDC Black 3+VDC White 4 Not Used Not Used 5 Not Used Not Used 6 Not Used Not Used 7 Not Used Green

FIG. 5

14 332298B

Installation

(1)

(2)

(3)

(4)

(5)

(6)

(7)

Fuse

12V-pump - 7.5A - Graco kit #571039 24V pump - 4A - Graco kit #571040

Example Wiring Diagram

Connector on Housing

Connector on Cable

(1)

(3)

(2)

(7)

(6)

(5)

(4)

Power CPC DC - 5 Wire

Part No.: 126218: 15 ft (4.5 m) Part No.: 126219: 20 ft (6.1 m) Part No.: 126220: 30 ft (9.1 m)

NOTE: An Illuminated Remote Run Button Kit: 571030 -

12V or 571031- 24V, for starting a manual run cycle if used in conjunction with a 5-wire CPC cable, is available from Graco. Contact your local Graco distributor or Graco Customer Service for additional information about these kits.

Pin and Related Wire Color(F

IG. 6)

Pin Pin Name Color

1 Not Used Not Used 2-VDC Black 3+VDC Red 4LIGHT White 5 MANUAL ORANGE 6 Not Used Not Used 7 Not Used Green

FIG. 6

332298B 15

Installation

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Part No. 124333: Cable Pin Out (M12)

Wire Colors

Item No. Color

1Brown 2White 3Blue 4Black

Part No. 124300: Field Wireable Pin Out (M12)

Wire Colors

Item No. Color

1 2 3 4

Brown

White

Blue

Black

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FIG. 8

FIG. 7

16 332298B

Installation

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Part No. 124594: 4 Pin Eurofast Field Wireable Connector

FIG. 9

Part No. 124595: 5 Pin Eurofast Field Wireable Connector

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FIG. 10

332298B 17

Setup

Pressure Relief

Follow the Pressure Relief Procedure whenever you see this symbol.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

Relieve pressure in system using two wrenches working in opposite directions on pump element and pump element fitting to slowly loosen fitting only until fitting is loose and no more lubricant or air is leaking from fitting.

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

Connecting to Auxiliary Fittings

NOTICE

Do not attach unsupported equipment to auxiliary fittings such as fill ports and pump element. Attaching unsupported equipment to these fitting can result in irreparable housing damage.

• Always use two wrenches working in opposite directions when connecting anything to pump element or auxiliary fittings. See F example.

• Torque pump element fittings to 50 in. lbs (5.6 N•m).

• When connecting pump element into housing torque to 50 in. lbs (5.6 N•m).

Pressure Relief Valves

To prevent over-pressurization, which can result in equipment rupture and serious injury, a pressure relief valve appropriate for the lubrication system must be installed close to every pump outlet to alleviate unintended pressure rises in the system and protect the G3 pump from damage.

IG. 11 for an

• Only use a pressure relief valve that is rated for no more than the working pressure of the G3 pump it is installed on. See Technical Data, page 34.

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

NOTE: A pressure relief valve can be purchased from

FIG. 11

18 332298B

Graco. See Parts, page 38.

Setting Pump Outlet Volume

NOTE:

• Before making any adjustments to pump volume, Relieve Pressure following procedure on page 18.

• Only use Graco supplied spacers to control output volume.

Setup

• It may be necessary to repeat this outlet volume setup procedure after the pump is operating to re-adjust the volume of dispensed fluids.

1. Use a wrench to turn pump element counter-clockwise to loosen. Do not remove entire pump element. Only back pump element out enough to allow spacer to be slid on or off.

NOTE: If needed, remove or insert spacers to achieve required pump output volume. A tool may be needed to facilitate removal.

Pump volume control is set using either no (0) spacers, 1 or 2 spacers (F

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

No. Spacers

IG. 12).

Output Volume / Minute

cubic inches cubic cm

20.122

10.183

00.254

FIG. 12

Loading Grease

To ensure optimal performance from the G3:

• Only use NLGI #000 - #2 greases appropriate for your application, automatic dispensing, and the equipment’s operating temperature. Consult with machine and lube manufacturer for details.

• The reservoir can be filled using a hand operated pump, pneumatic pump or electric transfer pump.

• Do not overfill (F

• Do not operate G3 without reservoir attached.

• Always clean fitting (D) with a clean dry cloth prior to filling reservoir. Dirt and/or debris can damage pump and/or lubrication system.

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

IG. 14).

NOTICE

NOTE:

• The amount of dispensed volume can vary depending on external conditions such as lubricant temperature and back pressure from downstream connections.

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

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

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

332298B 19

Setup

max fill line

vent hole

Models without a follower plate:

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

FIG. 13

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

Start pump by pressing the manual run button.

3. Fill reservoir with NLGI grease to max fill line.

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

Start pump by pressing the manual run button.

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

FIG. 15

NOTE: Vent port, located in rear of reservoir, should not

be used as an overfill port/indicator.

4. Remove fill hose.

IG. 15) and

Changing Greases

FIG. 14

4. Remove fill hose.

Models with a follower plate:

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

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

When changing greases, always use compatible fluids or greases.

Filling Oil Unit

• Only use oil appropriate for your application, automatic dispensing, and the equipment’s operating temperature. Consult with machine and lube manufacturer for details.

• The reservoir can be filled using a hand operated pump, pneumatic pump or electric transfer pump.

• Do not overfill (F

• Do not operate G3 without reservoir attached.

• Only use oils with viscosity at least 40 cSt.

IG. 16).

20 332298B

FIG. 16

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1. Remove fill cap (a).

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

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

Priming

Quick Setup Guide

FIG. 17

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

IG. 18).

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

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

Quick Setup Guide

IG. 17).

FIG. 18

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

IG. 17).

332298B 21

Pro Model Setup

OFF

HH MM

SS ##

MM : SS HH : MM

DISPLAY

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

indicates type of measurement unit you are setting; i.e., HH is hours.

• A blinking number on the display indi-

cates the G3 is in SETUP MODE.

• In RUN MODE displayed numbers count

up or down. See Time ON and Time OFF.

ON TIME

• LED lights when ON Time

sequence is running.

• Display shows time as MM:SS

(minutes and seconds). i.e., 08:30 is 8 minutes: 30 seconds.

• Times lubrication cycle.

OFF TIME

• LED lights when OFF Time sequence is

running.

• Value is entered in HH:MM.

• Displays in HH:MM (hours and minutes)

when > 1 hour.

• Displays in MM:SS (minutes and second)

ALARM ICONS

LED next to icon lights when a fault / warning event occurs during a run cycle. See page 30 for a complete description of these alarm scenarios.

LOCK ICON

• LED next to icon lights indi-

cating PIN is required to enter setup.

• In SETUP MODE LED

lights when setting up the

PRELUBE

LED next to icon lights indicating Prelube function is enabled.

LEFT DIRECTION ARROW / RESET

• In SETUP MODE, moves cur-

sor in display one field to the left.

• In RUN MODE: single press

clears warning.

• In ALARM MODE: pressing and

holding for 3 seconds clears

RIGHT DIRECTION ARROW / MANUAL RUN / ENTER:

• In SETUP MODE, saves

entry, moves cursor in display one field to the right or to the next setup step.

• In RUN MODE starts a man-

ual run cycle.

UP and DOWN ARROW

• Hold both the UP and DOWN ARROW but-

tons down together for 3 seconds to enter SETUP MODE.

• In SETUP MODE, increases or decreases

number values shown in display.

Pro Model Setup

Control Panel Overview (FIG. 19)

NOTE: Programming instructions begin on page 23.

FIG. 19

22 332298B

Pro Model Setup

Instructions

Powering Units With Controllers

By default, units with controllers are set to operate in a timed mode with 1 minute of ON time and 8 hours of OFF time. The unit should be powered up in OFF mode, counting down from the 8 hours. If the unit powers up in ON mode and has not been primed, hold the reset button located on the control panel (example shown on the right) for 1 second to move to the OFF mode.

The Pro Model uses a timer to regulate how long a pump cycle runs and the length of time the pump rests between cycles.

NOTE:

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

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

• After 60 seconds of no activity, the device returns to RUN MODE in the OFF Time cycle and the OFF Time restarts counting down the total programmed amount of time. It does not resume the countdown from the point where the cycle was interrupted when you entered SETUP MODE.

Entering Setup Mode

Press both the UP and DOWN ARROW buttons together for 3 seconds to enter the SETUP MODE.

NOTE: If the lock LED is lit after entering Setup Mode and four 0000’s are displayed, the unit has a PIN Code lock out enabled. See Entering a PIN Code to Access Setup Mode for instructions on entering a value.

Entering a PIN Code to Access Setup Mode

The G3 controller does not require a user to provide a PIN code to access the programming features of the unit. However, Graco understands that some users may want to protect the program settings and therefore, an option for adding PIN Code authorization is available. The instructions for setting a PIN Code are provided in the Advanced Programming section of this manual. See page 26.

To enter the PIN Code:

1. Press both the UP and DOWN ARROW buttons for 3 seconds.

2. The LED next to the LOCK ICON on the display lights and the 4 zeros appear on the display indicating the system requires a PIN Code entry to access the G3 in SETUP MODE.

3. The cursor is automatically positioned to enter the first character of the PIN Code. Use the UP and DOWN ARROW buttons to move up and down through the numbers 0-9 until the first number in the PIN code is displayed in the field.

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

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

If the PIN Code you entered is correct, the first editable character on the display will flash.

NOTE: A blinking field on the display indicates the G3 is in SETUP MODE. In RUN MODE numbers on the display will not blink.

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).

332298B 23

Pro Model Setup

• An LED flashes under either MM when programming minutes OR SS when programming seconds.

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

• The total amount of ON Time cannot exceed 30 minutes. If a value greater than 30 minutes is entered, the RED alarm LED lights and the value must be updated.

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

Programming ON Time

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

utes you must program a leading zero in the first number field and press the ENTER button to save the zero selection.

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

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.

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

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

The G3 automatically switches to the OFF Time SETUP MODE.

OFF Time

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

• OFF Time is set in Hours and Minutes (HH: MM).

• An LED flashes under either HH when programming hours OR MM when programming minutes.

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

• The total amount of OFF Time must be at least twice as long as the programmed ON Time. If a value less than twice the ON Time is entered, the RED alarm LED lights and the value must be updated.

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

Programming OFF Time

NOTE: When programming a time of less than 10 hours you must program a leading zero in the first

number field and press the ENTER button to save the zero selection.

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.

24 332298B

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.

Pro Model Setup

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

3. Use the UP or DOWN ARROW button to scroll through numerals 0 to 9 until the desired number appears in the second HH number field.

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

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

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

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

Prelube

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

4. If you want to set a prelube delay time, press the DOWN ARROW button to change OFF to ON on the display.

Prelube Delay

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

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

1. Prelube Delay is set in MM:SS (minutes and seconds). To set the time use the UP or DOWN ARROW button to scroll through numerals 0 to 5 until the desired number appears in the first MM (minutes) field.

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

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

ON - The unit begins a pump cycle.

Setting Prelube

1. After you set the OFF Time information and press the ENTER button, the G3 automatically switches to the Prelube setup.

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

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

3. Press the ENTER button to set the selection.

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

3. Use the UP or DOWN ARROW button to scroll through numerals 0 to 9 until the desired number appears in the second MM number field.

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

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

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

6. After pressing the ENTER button to set the last SS field the G3 automatically switches to the RUN MODE.

332298B 25

Advanced Programming

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

Advanced

Option

A1 Lockout

A2 Low Level

Setting Format/ Description Why Use This?

Secures setup modes with PIN Prevents unauthorized users to adjusting settings. Code (Optional)

MM:SS (minutes:seconds) sets Alarm Time

amount of time between Low

Level Warning to Low Level Fault.

Default = 3 minutes

Entering a PIN Code for the First Time

A1-Setting Up PIN Code

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

1. Press the UP ARROW button for 10 seconds.

The LED next to the LOCK ICON on the display lights, indicating you have entered the PIN Mode.

2. The word OFF appears in the display. Press the UP or DOWN ARROW button to change this to ON.

3. Press the ENTER button to enter the PIN Code.

4. The cursor automatically is positioned to entered the first character of the PIN Code. Use the UP and DOWN ARROW buttons to move up and down through the numbers 0-9 until the first number in the PIN code is displayed in the field.

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.

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

7. Press the ENTER button to save the PIN Code and exit Advanced Setup.

Entering Advanced Setup

Press the UP ARROW button for 10 seconds.

If the G3 was previously set up to require a PIN Code, the LED next to the LOCK ICON lights, indicating a PIN Code is required.

1. The cursor is automatically positioned to enter the first character of the PIN Code. Use the UP and DOWN ARROW buttons to move up and down through the numbers 0-9 until the first number in the PIN code is displayed in the field.

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

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

If the PIN Code you entered is correct, the first editable character on the display will flash.

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

26 332298B

Advanced Programming

OFF

HH MM

SS ##

MM : SS HH : MM

Selecting Advanced Setup Options

1. Press the UP or DOWN ARROW button to move up or down through Advanced Options A1 and A2.

2. Press the ENTER button to set the selection.

A2 - Low Level Alarm Time

Pump ON mode only.

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

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

Fault, and Low Level LED illuminate.

1. To set the time use the UP or DOWN ARROW button to scroll through numerals 0 to 9 until the desired number appears in the first MM (minutes) field.

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

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.

FIG. 20

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

utes you must program a leading zero in the first number field and press the ENTER button to save the zero selection.

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.

332298B 27

Run Mode

OFF

HH MM

SS ##

MM : SS HH : MM

OFF

HH MM

SS ##

MM : SS HH : MM

Run Mode

Time Control

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

• 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 of 1 hour and 32 minutes before the lubrication cycle begins.

IG. 21).

IG. 21 shows an OFF Time

• 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

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

• The example shown in F of 8 minutes and 42 seconds before the lubrication cycle ends.

IG. 22 shows an ON Time

IG. 22).

FIG. 22

• 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-

FIG. 21

minated (F

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

IG. 21).

Manual Run Cycle

To run an extra (non-programmed) lubrica-

28 332298B

tion cycle, push the Manual Start button.

Additional Controls

OFF

HH MM

SS ##

MM : SS HH : MM

Prelube / Prelube Delay

In all models a power OFF/ON cycle can be controlled with the Prelube and Prelube Delay functions.

Prelube

The Prelube function has been selected. Prelube delay is set to 00:00:

• Power to the unit cycles OFF then ON.

• Unit immediately begins a lubrication cycle.

• Pro Model - display shows ON Time (See Time Control, page 28).

Prelube Delay

The Prelube function has been selected. Prelube delay is set to something other than 00:00:

Run Mode

• Power to the unit cycles OFF then ON.

• Unit immediately begins the Prelube Delay count down until the lubrication cycle begins.

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

• The Prelube LED lights (F

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

IG. 23).

IG. 23

Manual Run Cycle

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

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

332298B 29

Alarms

Any time a Fault / Warning occurs, a combination of LED’s will illuminate to notify you there is a problem and help identify the kind of Fault / Warning has occurred.

• Faults and Warnings will not automatically clear.

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

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

Fault / Warning Scenarios

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

Alarm Type What it Looks Like What it Indicates Solution

Low Level Warning

HH MM

MM : SS HH : MM

SS ##

OFF

Level of lubricant in reservoir is low and addi-

tional lubricant needs to be added.

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

Add lubricant to reservoir.

After lubricant is added, press the RESET button to clear the warning.

Low Level Fault

HH MM

MM : SS HH : MM

SS ##

OFF

Level of lubricant in reservoir is low and addi-

tional lubricant needs to be added.

Unit stops pumping and displays amount of accumulated time since the

Add lubricant to reservoir.

After lubricant is added press and hold the RESET button to clear fault.

alarm was triggered.

If repriming pump is required, the low level alarm time should be decreased. See A-2: Advanced Programming, Low Level Alarm Time page 27.

30 332298B

Troubleshooting

Problem Cause Solution

Troubleshooting

Unit does not power on

Unit does not power on (DC models only)

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

Incorrect/loose wiring Refer to Installation instructions, page

Tripped external fuse due to internal component failure

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

Tripped internal power supply fuse due to power supply failure

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

Time entered was misinterpreted as MM:SS instead of HH:MM (or visa versa)

Reservoir retaining tabs are cracked or broken

Reservoir is being pressurized during filling

Contact Graco Customer Service.

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

Replace fuse.

Contact Graco Customer Service.

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

Verify the unit was programmed as intended, referencing programming instructions. Note the dot designation for hours, minutes, seconds on the top row of the display.

Replace reservoir.

Ensure vent hole is not plugged.

If problem persists, contact Graco Customer Service or your local Graco distributor for assistance.

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

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)

Dim display, unit is not operating

332298B 31

Failed motor Replace unit.

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

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

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

Add grease following Loading Grease instructions, page 19. Ensure air is purged.

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

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

Maintenance

Frequency Component Required Maintenance

Daily and at refill Zerk Fittings

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

Daily Display Keep display clean using a clean

Monthly External Wiring Harness Verify external harnesses are

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

using a clean dry cloth.

dry cloth.

secure.

32 332298B

Parts - 2 Liter Models

40a

Follower Plate Models Only

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

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

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

40b

Low Level Grease Models Only

Low Level Oil Models Only

Parts - 2 Liter Models

332298B 33

Parts - 4 Liter and Larger Models

40a

Follower Plate Models Only

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

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

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

40b

Low Level Grease Models Only

Low Level Oil Models Only

Parts - 4 Liter and Larger Models

34 332298B

Parts

Ref Part Description Qty

1 BASE, three pump housing 1

3 278142 COVER, bottom, with seal 1

4 115477 SCREW, mach, torx pan hd 9

12 127079

13 124396

14 PLATE, ricer 1

15 BEARING, ball 1

18 16F368

RECT-RING, included in Kit 571042, 571069, 571179

O-RING, 258, included in Kit 571042, 571044, 571045, 571069, 571179

PADDLE, stirring, 2 Liter models without follower plate - models 96G011, 96G013, 96G027, 96G028, 96G029, 96G033, 96G034, included in Kit 571044, 96G178

PADDLE, stirring, 4 Liter models without follower plate - models 96G068, 96G075, 96G135, 96G137, 96G139, 96G147, 96G149

PADDLE, stirring, 8 Liter models without follower plate - models 96G069, 96G076, 96G136, 96G138, 96G140, 96G148, 96G150

PADDLE, stirring, 12 Liter models without follower plate - models 96G077, 96G163

PADDLE, stirring, 16 Liter models without follower plate - models 96G078, 96G167

PADDLE, stirring, 2 Liter models with follower plate - models 96G012, 96G014, included in Kit 571045

PADDLE, stirring, 4Liter models with follower plate - models 96G073, 96G082

PUMP, element, 96G073, 96G082 included in Kit 571041

SPACER, stroke adjust, included in Kit 571041

Ref Part Description Qty

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

PADDLE, low level, models 96G011-96G014, 96G033, 96G034, 96G068, 96G069,

23 278136

27 123025

30 ‡

31 119228

33 16A579 LABEL, safety 1

34 16A578

258760

96G073, 96G075-96G078, 96G082, 96G147, 96G148, 96G149, 96G150, 96G163, 96G167

SCREW, M6, models 96G011-96G014, 96G033, 96G034, 96G068, 96G069, 96G073, 96G075-96G078, 96G082, 96G147, 96G148, 96G149, 96G150,96G163, 96G167

BOARD, circuit, Pro, models 96G011 - 96G014, 96G027-96G029, 96G033, 96G034, 96G069-96G073, 96G075-96G082, 96G135-96G140, 96G147, 96G148, 96G150, 96G163, 96G167

SCREW, machine, flat head, models 96G011-96G014, 96G027-96G029, 96G033, 96G034, 96G069-96G072, 96G075-96G082, 96G135-96G140, 96G147, 96G148, 96G149, 96G150, 96G163, 96G167

LABEL, overlay, models 96G011-96G014, 96G027-96G029, 96G033, 96G034, 96G069-96G072, 96G075-96G082, 96G135-96G140, 96G147,-96G150, 96G163, 96G167

332298B 35

Parts

Ref Part Description Qty

WIPER, stirring, models without follower plate - models 96G011, 96G013, 96G027-96G029, 96G033, 96G034, 96G068, 96G069, 96G075-96G078, 96G135-96G140, 96G147,

96G148, 96G149, 96G150, 96G163, 96G167 included in Kit 571044

WIPER, stirring, models with follower plate - models 96G012, 96G014, 96G073, 96G082 included in Kit 571045

36 LABEL, brand 1

FITTING, Zerk, grease, not

37 123741

included on models 96G070-96G072, 96G079-96G081

RESERVOIR, 2 liter, grease, 96G011-96G014,

40a 24E984

96G027-96G029, 96G033, 96G034 included in Kit 571042, 571069

RESERVOIR, 2 liter, oil,

40b 16G021

96G070, 96G079, included in Kit 571179

RESERVOIR, 4 liter, grease, 96G068, 96G073, 96G075,

40a 24B702

96G082, 96G135, 96G137, 96G139, 96G147, 96G149, included in Kit 571183

40b 16G020

RESERVOIR, 4 liter, oil, 96G071, 96G080

RESERVOIR, 8 liter, grease,

40a

96G069, 96G076, 96G136, 96G138, 96G140, 96G148, 96G150

RESERVOIR, 8 liter, oil,

40b

96G072, 96G081, included in Kit 571182

40a

278139

16F472

RESERVOIR, 12 liter, 96G077, 96G163

RESERVOIR, 16 liter, 96G078, 96G167

SEAL, follower plate, 2 liter models 96G012, 96G014

SEAL, follower plate, 4 liter models 96G073, 96G082

Ref Part Description Qty

PLATE, follower, 2 liter models

96G012, 96G014 PLATE, follower, 4 liter models

96G073, 96G082

ROD, follower plate, 2 liter models 96G012, 96G014

ROD, follower, 4 liter models

96G073, 96G082 SPRING, compression, 2 liter

models 96G012, 96G014 SPRING, compression, 4 liter

models 96G073, 96G082

BAFFLE, low level, 2 liter models

45† 24D838

96G011, 96G013, 96G033,

96G034

†24E246

BAFFLE, low level, 4 liter models 96G068, 96G075, 96G147,

96G149 BAFFLE, low level, 8 liter models

†24F836

†24F923

†24F924

96G069, 96G076, 96G148, 96G150

BAFFLE, low level, 12 liter models 96G077

BAFFLE, low level, 16 liter models 96G078, 96G167

BEARING, sleeve, models 96G011-96G014, 96G033-96G034, 96G068,

57 117156

96G069, 96G073,

1 96G075-96G078, 96G082, 96G147-96G150, 96G163,

96G167 LABEL, models 96G013,

58 196548

96G014, 96G029, 96G075-96G082, 96G139, 96G140

WASHER, low level, models 96G011-96G014,

60 16D984

96G033-96G034, 96G068, 96G069, 96G073, 96G075-96G078, 96G082, 96G147-96G150, 96G163,

96G167

36 332298B

Parts

Ref Part Description Qty

RESERVOIR, mid-section, 8 liter models 96G069, 96G072, 96G076, 96G081, 96G136,

96G138, 96G140, 96G148,

96G150 RESERVOIR, mid-section, 12

liter models 96G077, 96G163 RESERVOIR, mid-section, 16

liter models 96G078, 96G167

ADAPTER, reservoir, models 96G068, 96G069, 96G071- 96G073, 96G075-

96G078, 96G080-96G082,

1 96G135-96G140, 96G147-96G150, 96G163, 96G167

NUT, oil, models 96G070,

66 126417

96G071, 96G072, 96G079, 96G080, 96G081

FLOAT, oil, models 96G070,

67 24N806

96G071, 96G072, 96G079, 96G080, 96G081

CABLE,15 ft (4.5 m), SOOW

126217

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

1 ing Diagram, page 14)

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

126218

pos, 5 pin, 90 deg, (See Wiring

Diagram, page 15)

200

126219

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

ing Diagram, page 15) CABLE, 30 ft (9.1m) SOOW, w/7

126220

pos, 5 pin, 90 deg, (See Wiring Diagram, page 15)

16U790

CABLE, DIN, bare, (See Wiring Diagram, page 12)

CABLE, M12, 15 ft., 4 wire,

201

124300

124333

straight male to flying leads (See Wiring Diagram, page 16)

CABLE, M12, 15 ft., 4 wire, straight male to female (See Wiring Diagram, page 16)

202

124301

124594

124595

CONNECTOR, Eurofast, fem, straight, 4 Pin

CONNECTOR, Eurofast, 4 Pin (see wiring diagram, page 17)

CONNECTOR, Eurofast, 5 Pin (see wiring diagram, page 17)

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

 Also order Ref 27, Part No. 123025 and Ref 60, Part No. 16D984

‡ For Pro Models Only - Also order Ref 31, Part No. 119228 and Ref 34, Part No. 16A578

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

332298B 37

Parts

ti15644

a = adjustment screw b = locking nut

Pressure Relief Valves

Important Information regarding Pressure Relief Valve 16C807.

 Pressure Relief Valve 16C807 can only be used on the G3 Pump. It is not intended for use with any other

products.

The pressure relief valve uses a pressure adjustment screw (a) to set the pressure release point. It

is not intended as a way to relieve pressure during normal operation, but as a protective

measure in the event there is an unintended pressure increase in the system. Do not use this pressure relief valve a means of relieving pressure in day-to-day, normal cycle operation.

The pressure adjustment screw will require periodic adjustments. Whenever the valve is set/adjusted (after the set point is found) it is important to ensure that the valve is not bottomed out and there is at least 1/2 turn of adjustment remaining. This is determined by turning the screw (a) 1/2 turn and then back turning it out again.

NOTE: Turning adjustment screw (a) clockwise increases pressure.

Part Description Qty

VALVE, pressure relief, 500-3500 psi (3.44 MPa, 34.4 bar - 24.1 MPa, 241

16C807

563156

563157

563158

563159

563160

563161

bar), Set pressure 3000 psi + (20.68 MPa, 206.8 bar +

10%

10%)

Included in Kit 571028, 571071 VALVE, pressure relief, 750 psi (5.17

MPa, 51.71 bar) VALVE, pressure relief, 1000 psi

(6.89 MPa, 68.95 bar) VALVE, pressure relief, 1500 psi

(10.34 MPa, 103.42 bar) VALVE, pressure relief, 2000 psi

(13.78 MPa, 137.89 bar) VALVE, pressure relief, 2500 psi

(17.23 MPa, 172.36 bar) VALVE, pressure relief, 3000 psi

(20.68 MPa, 206.84 bar)

Fuses

Part Description Qty

571039 FUSE, 12 volt DC

571040 FUSE, 24 volt DC

Installation and Repair Kits

Manual

Kit No. Description

571026 KIT, output union, 3 pump 571063 KIT, output union, 2 pump

KIT, return to reservoir NPT,

571028

includes pressure relief valve 16C807

KIT, return to reservoir BSPP,

571071

includes pressure relief valve 16C807

571030

571031

571032

571033

KIT, remote manual run, 12 volt DC

KIT, remote manual run, 24 volt DC

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

KIT, remote manual run, 24 volt DC with cable

571036 KIT, cover with “G” label NA

571041

571042

KIT, pump element, includes Ref 17, 18, 33

KIT, repair, 2 liter reservoir, includes Ref 13, 36, 40

KIT, repair, 2 liter reservoir, for

571069

models with follower plate, includes Ref 13, 36, 40

KIT, replacement, paddle, 2 liter,

571044

for models without follower plate, includes Ref 13, 16, 35, 57

KIT, replacement, paddle, 2 liter,

571045

for models with follower plate, includes Ref 13, 16, 35,40a, 42, 57

KIT, replacement, paddle, 4-16

571046

liter, for models without follower plate, includes Ref 13, 16, 35, 57

KIT, replacement, paddle, 4 liter,

571047

for models with follower plate, includes Ref 13, 16, 35, 57

Number

3A0523

3A0525

3A0528

3A0533

3A0534

3A0535

38 332298B

Manual

Kit No. Description

571058 KIT, output adapter, NPT 571070 KIT, output, adapter, BSPP

Number

3A0522

571060 KIT, fill, zerk, leakproof NA

571179

571182

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

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

3A0534

KIT, repair, reservoir, grease, 4

571183

liter models, includes Ref 13, 36, 40b

Parts

332298B 39

Technical Data

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

Power

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

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

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

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

Fluid

Grease Models Grease NLGI 000 - #2

Oil Models At least 40 cSt oil.

Pumps Up to 3

Pump Output

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

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

IP Rating IP69K

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

Weight (Dry - includes power cord and plug)

Without follower plate 13.3 lbs (6.03 kg)

With follower plate 14.2 lbs (6.44 kg)

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

Sound Data <60 dB

0.12 in.

0.18 in.

0.25 in.

carbon steel, alloy steel, stainless steel, nitrile rubber (buna-N), bronze, nickel plated alnico, chemically lubricated acetal, aluminum, PTFE, Grillamid

(2 cm3) / minute per outlet - 2 spacers

(3 cm3) / minute per outlet - 1 spacer

(4 cm3) / minute per outlet - 0 spacers

Dimensions

Model

2L 13.25 33.65 8.00 20.32 9.00 22.86 4L 14.50 36.83 9.25 23.50 10.00 25.40

8L 18.50 47.00 9.25 23.50 10.00 25.40 12L 23.00 58.42 9.25 23.50 10.00 25.40 16L 27.50 69.85 9.25 23.50 10.00 25.40

40 332298B

Inches cm Inches cm Inches cm

Height Width Depth

0.367inch

9.3 mm

2x Ø 0.366 inch

9.3 mm

3.544 inch

90.0 mm

7.087 inch

180.0 mm

1.180 inch

30.0 mm

3.268 inch

83.0 mm

0.722 inch

18.3 mm

2x Ø 0.366 inch

9.3 mm

3.189 inch

81.0 mm

6.378 inch

162.0 mm

3.740 inch

95.0 mm

0.708 inch

18.0 mm

Option 1

Option 2

Technical Data

Mounting Pattern

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

FIG. 24

332298B 41

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to

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

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

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

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 612-623-6928 or Toll Free: 1-800-533-9655, Fax: 612-378-3590

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

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

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

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

Original instructions. This manual contains English. MM 332298

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

revised April 2014

Graco 332298B User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

Part / Model Numbers

2 Liter Models

4 Liter Models

8 Liter Models

12 Liter Models

16 Liter Models

Understanding the Model Number

Warnings

Installation

Typical Installation

Choosing an Installation Location

System Configuration and Wiring

Setup

Connecting to Auxiliary Fittings

Setting Pump Outlet Volume

Loading Grease

Filling Oil Unit

Priming

Quick Setup Guide

Pro Model Setup

Control Panel Overview (FIG. 19)

Instructions

Advanced Programming

Run Mode

Time Control

Alarms

Fault / Warning Scenarios

Troubleshooting

Maintenance

Parts - 2 Liter Models

Parts - 4 Liter and Larger Models

Parts

Technical Data

Dimensions

Graco Standard Warranty

Graco Information