Graco G3-G-24MX-2L0L00-10CV00R0, G3-G-24MX-2LFL00-10CV00R0, G3-G-ACMX-2LFL00-1D0V0000, G3-G-ACMX-2L0L00-1D0V0000, G3-G-12MX-2L0L00-1DMVA2R3 Instructions Manual

Instructions

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

3132066

24V and 110-240VAC Pumps ONLY.

G3 Max Automatic

332305J

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) Pump Output Pressure
5000 psi (34.4 MPa, 344.7 bar) Maximum Working Pressure - Auto-Fill Shut Off

EN

Important Safety Instructions

Read all warnings and instructions in this
manual. Save all instructions.

Contents

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

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

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

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

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

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

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

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

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

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Component Identification . . . . . . . . . . . . . . . . . . 9

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

Typical Installation -

With Remote Fill Manifold . . . . . . . . . . . . . . 11

Optional Installation -

Without Remote Fill Manifold . . . . . . . . . . . 12

System Configuration and Wiring . . . . . . . . . . . 13

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Connecting to Auxiliary Fittings . . . . . . . . . . . . . 22

Setting Pump Outlet Volume . . . . . . . . . . . . . . . 23

Loading Grease . . . . . . . . . . . . . . . . . . . . . . . . 23

Auto-Fill Shut Off . . . . . . . . . . . . . . . . . . . . . . . . 25

Filling Oil Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Quick Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . 29

Max Model Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Control Panel Overview . . . . . . . . . . . . . . . . . . 30

Programming the Max Model . . . . . . . . . . . . . . 31

PUMP OFF / REST Setup . . . . . . . . . . . . . . . . 36

™

DMS
Storing Pump Program Settings to the

Uploading Pump Program Settings to the

Operation / Data Log . . . . . . . . . . . . . . . . . . . . . . . 41

System Event Log . . . . . . . . . . . . . . . . . . . . . . . 41

Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Functional Summary . . . . . . . . . . . . . . . . . . . . . 45

Technical Summary . . . . . . . . . . . . . . . . . . . . . 47

Advanced Programming . . . . . . . . . . . . . . . . . . . . 48

Models with Firmware 6.03 and later. DMS Models

Models with Firmware 6.06 and later for non-DMS

Models Only . . . . . . . . . . . . . . . . . . . . . 39

Flash Drive . . . . . . . . . . . . . . . . . . . . . . . . . 39

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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

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

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Parts - 2 Liter Models . . . . . . . . . . . . . . . . . . . . . . . 80

Parts - 4 Liter and Larger Models . . . . . . . . . . . . . 81

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

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

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

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 88

Graco Information . . . . . . . . . . . . . . . . . . . . . . . 88

2 332305J

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 Number
identifies the distinct features of a specific G3 Pump. To help you understand each component that makes up the
Model Number see Understanding Your Model Number, page 5. The tables below shows the relationship between
each Part Number and its related Model Number.

2 Liter Models 4 Liter Models

Part Model Numbers

96G017 G3-G-24MX-2L0L00-10CV00R0 X
96G018 G3-G-24MX-2LFL00-10CV00R0 X
96G019 G3-G-ACMX-2L0L00-1D0V0000 X
96G020 G3-G-ACMX-2LFL00-1D0V0000 X
96G021 G3-G-12MX-2L0L00-1DMVA2R3
96G023 G3-G-24MX-2L0L00-1DMVA2R3 X
96G024 G3-G-24MX-2LFL00-1DMVA2R3 X
96G025 G3-G-ACMX-2L0L00-1DMVA2R3 X
96G026 G3-G-ACMX-2LFL00-1DMVA2R3 X
96G030 G3-G-12MX-2L0L00-10C00000
96G031 G3-G-24MX-2L0L00-10C000R0 X
96G032 G3-G-ACMX-2L0L00-1D000000 X

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

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

96G037 G3-G-ACMX-2L0L00-1D00A000
96G098 G3-G-12MX-2L0L00-UDMVA1R2
96G107 G3-A-24MX-2L0L00-1DMVA2R3 X
96G110 G3-G-24MX-2L0L00-UDMVA1R2 X
96G115 G3-G-24MX-2LFL00-UDMVA1R2 X

96G122
96G125 G3-G-ACMX-2L0L00-UDMVA1R2 X

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

96G174 G3-A-ACMX-2L0L00-UDMVA1R2
96G178 G3-G-24MX-2L0L00-0D00A100 X
96G190 G3-A-24MX-2L0L00-UDMVA1R2 X
96G206 G3-G-24MX-24L0L07-0D00A000 X

G3-A-ACMX-2L0L00-1DMVA2R3 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 X
96G111

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

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

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

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

X

X

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

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 G3-6-12MX-4L0005-10CV0000

G3-G-24MX-4L0L00-UDMVA1R2

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

332305J 3

Part / Model Numbers

8 Liter Models 12 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

96G119

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 X

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

G3-G-24MX-8L0L00-UDMVA1R2

G3-G-ACMX-8L0L00-1DMVA2R3

Part Model Numbers

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

96G105 G3-G-24MX-120L00-1DMVA2R3 X
96G120 G3-G-ACMX-120L00-1DMVA2R3 X
96G164 G3-G-24MX-120L05-10CV00000 X
96G165 G3-G-24MX-120L05-U0CV0100 X
96G231 G3-A-12MX-120L08-V0C0010M
96G246 G3-A-24MX-120L08-U0C0010M

16 Liter Models

Part Model Numbers

96G106

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

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

X

X

X

X

X

X

X

X

X

4 332305J

Part / Model Numbers

k

m

n

p

h

j

i

g

DMS™ Model

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- MX

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

• MX = Max (Cycle) Control

Code cc: Reservoir Capacity (Liters)

• 2L = 2 Liters

• 4L = 4 Liters

• 8L = 8 Liters

• 12 = 12 Liters

• 16 = 16 Liters

Code d: Follower Plate Installed

• F = Follower Plate Installed

• 0 = No Follower Plate

• A = Auto-Fill Shut Off

Code e: Low Level Option

• L = Low Level with Controller

• 0 = No Low Level monitoring

Code ff: Options

• 00 = No Options

• 03 = Powered Alarm Contact

• 05 = 5 Pin CPC power cable

• 07 = No Power Cord

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

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

• 1, 2, 3 = Sensor Number

• R = Remote Manual Run

• M = Machine Count

• A = Alarm Output

• V = Vent Valve

• 0 = Not populated

• U = USB Port

IG. 1 for these locations.

FIG. 1

332305J 5

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 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.

6 332305J

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 surgi-

cal treatment.

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

• Do not put your hand over the fluid outlet.

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

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

• Tighten all fluid connections before operating the equipment.

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

PRESSURIZED EQUIPMENT HAZARD

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

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

• Follow Pressure Relief Procedure in this manual before servicing.

PLASTIC PARTS CLEANING SOLVENT HAZARD

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

property damage.

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

• See Technical Data in this and all other equipment instruction manuals. Read fluid and solvent
manufacturer’s SDSs 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 eye wear, and hearing protection.

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

332305J 7

Installation

Installation

Unpacking

NOTICE

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 follow­ing 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.

Choosing an Installation Loca­tion

• Use designated mounting holes and provided
configurations only.

• Always mount the G3 oil models upright.

• If the G3 grease model is going to be operated
in a tilted or inverted position for any period of
time, you must use a model that includes a fol­lower plate, otherwise the G3 must be mounted
upright. Refer to your model number to confirm
if a follower plate was installed on your pump.
See page 5, Understanding the Model Number
to identify this character in your model number.

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

• Some installations may require an additional
reservoir support bracket. See Table below for
bracket information.

In high vibration environments and when using
an AC model, additional dampening at mounting
point is necessary.

Part No Description

571159 Reservoir bracket and strap

125910 L-Bracket for pump

127665 USP to G-Series mounting bracket

AUTOMATIC SYSTEM ACTIVATION HAZARD

If the system is equipped with has an automatic timer
(user supplied) that activates the pump lubrication
system when power is connected or when exiting the
programming function, unexpected activation of the
system could result in serious injury, including skin
injection and amputation.

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

• 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 87. No other installation configuration
should be used.

8 332305J

Component Identification

A

D

H

I

B

E

F

J

G3-G-24NC-2L0A00-L0C00000

Grease Models with Follower
Plate

L

M

96GXXX

Oil Models

N

Grease Models

DMS

TM

Models

P

R

Auto-Fill Shut Off Models

Installation

FIG. 2:

Key:

AReservoir
B Pump Element (1 included. Can accommodate 3 total)
C Pressure Relief Valve (Not shown. Not included / required for

each outlet - Available from Graco. See Parts, page 83.)
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. Available

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

K Power Cord (not shown)

output volume per stroke) (also see F

from Graco. See Parts, page 84.)

IG. 21, page 23)

pages 5, Understanding the Model Number, for details)

L Follower Plate (grease models only / not available on all

grease models)

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

available on all grease models)
N Fill cap (oil models only)
P USB Port (DMS

R Auto-Fill Shut Off

™

Models only)

332305J 9

Installation

A

B

C

D

E

F

A

B

D

E

C

F

H

G

Typical Installation

Series Progressive Divider Valve Installations

FIG. 3

Injector Installations

FIG. 4

A Connected to fused power source
B Pressure relief valve (Not included/required for each outlet

- user supplied. See Parts, page 83)

C - Cycle indicator sensor cable (Divider Installations)

- Pressure switch cable (Injector Installations)

D - Series progressive divider valves (Divider Installations)

- Injectors (Injector Installations)

E To lube points

10 332305J

F - Proximity Switch (Divider Installations)

- Pressure switch (Injector Installations)

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

Parts, beginning on page 82.)

H Return to reservoir

Installation

E

D

C

F

P

N

K

H

J

M

L

A

R

Q

B

S

T

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.

FIG. 5

Key:

AG3 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.

332305J 11

Installation

E

F

J

S

B

C

D

A

L1

H

U

V

L

L2

W

Y

Optional Installation - Without 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.

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.

FIG. 6

Key:

AG3 Pump
B Auto-Fill Shut Off Valve
C Auto-Fill Inlet
D G3 Reservoir
E Remote Fill Reservoir
F Remote Fill Pump
HRelief 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.

12 332305J

System Configuration and Wiring

Installation

Grounding

The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static
sparking 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 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.

Fuses

NOTICE

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

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

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

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

Input Voltage Fuse Value Graco Kit No.

12 VDC

24 VDC 4 A 571040

7.5 A

571039

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.

• 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.

332305J 13

Installation

Alarm Output and Remote Illumination Response

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

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

Standard Remote

Alarm Output

(via DIN alarm relay

connector)

Illumination

(via 5 wire CPC power

cable)

Unit in OFF Mode Deactivated (off) Off Off
Unit in ON Mode Deactivated (off) On Green
Warning Condition (A11

OFF)
Low Level Indication (A9

OFF)
Fault Condition

(Advanced Programming
A7 OFF)

Fault Condition (Advanced
Programming A7 ON)

Activated (on)

See Warning or Fault Con­dition

Toggles On and Off once
per second

Activated (on)

Toggles On and Off once
per second

Toggles On and Off once
per second

Toggles On and Off once
per second

Toggles On and Off once
per second

Tri-Color Remote

Illumination

(via M12 Connector)

Yellow

See Warning or Fault Con­dition

Red

Red

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

Pin 4

Alarm

Low Level Warning
FIRMWARE 6.02 and above

Off*

(A7 OFF, A9 ON)
Low Level Warning

(A7 OFF, A9 OFF)
Low Level Fault

(A7 OFF, A9 OFF)
Low Level Fault

(A7 ON, A9 OFF)

*Firmware 6.04 and above for non-DMS models and 7.07 and above for DMS models. For A11 OFF the Alarm Pin 4 activates ON
during a warning. It is shown with A11 ON.

Off* Activated (On)

Toggles On and Off once
per second

Activated (On) Activated (On)

Toggles On and Off once
per second

Activated (On)

Pin 7

Low Level

14 332305J

Alarm Relay Response

N.O.

N.C.

N.O.

N.C.

1 second

No Faults or

Warnings

Installation

Output Tied to Common

Warning

(Advanced

Programming

Setting A11 OFF)

Fault

(Advanced

Programming A7

OFF)

Fault

(Advanced

Programming

Setting A7 ON)

N.O.

N.C.

N.O.

N.C.

Wiring and Installation Diagrams

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

Diagram Symbol Page #

Power DIN AC 16

Power DIN DC 16

Power CPC DC 17

Inputs (M12)

Vent Valve Outputs 19

Alarm Outputs 19

Illuminated Manual Run Input

332305J 15

Kits: 571030, 571031,
571032, 571033

18

Installation

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

Pin and Related Wire Color (FIG. 7)

Pin Pin Name Color

1 Line Black
2 Neutral White
3 Not Used Not Used

Ground Green

4

Power DIN DC - 15 foot

Pin and Related Wire Color (FIG. 8)

Pin Pin Name Color

1-VDC Black
2+VDC White
3

4

Not Used Not Used

Not Used Green

FIG. 7

FIG. 8

16 332305J

Installation

Power CPC DC -15 foot

Pin and Related Wire Color (FIG. 9)

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

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. Con­tact your local Graco distributor or Graco Customer Ser­vice for additional information about these kits.

Pin and Related Wire Color (F

Pin Pin Name Color

1

Not Used Not Used
2-VDC Black
3+VDC Red
4LIGHT White

Manual Run

5

6 Not Used Not Used
7 Not Used Green

Switch

IG. 10)

Orange

FIG. 10

FIG. 9

332305J 17

Installation

1 SW +

2 Not Used

3 SW -

4 Signal

(3)

(4)

(1)

(2)

Sink (NPN) 2 or 3 wire

1

2

3

4

Source (PNP) 2 or 3 wire

1

2

3

4

Dry Contacts

1

2

3

4

Example Wiring Diagram

Pin-outConnector on Housing

Pin and Related Wire Color (FIG. 11)
Wiring for “08” Option

CPC Pin Pin Name Wire Color

1 Not Used Not Used
2 -VDC/Com Black
3+VDC Red
4 Alarm White
5 Manual Orange
6 Not Used Not Used
7 Low Level Warning Green

Inputs (M12)

See Technical Data, page 85 for ratings.

FIG. 12

FIG. 11

18 332305J

Installation

FIG. 13

Vent Valve Outputs

See Technical Data, page 85 for ratings.

Alarm Outputs

DC example shown. See Technical Data,
page 85 for ratings.

FIG. 14

1

1.

332305J 19

Installation

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

Wire Colors (FIG. 15)

Item No. Color

1Brown
2White
3Blue
4Black

Part No. 124300: Male Flying Lead Pin Out
(M12)

Wire Colors (FIG. 16)

Item No. Color

1Brown
2White
3Blue
4Black

FIG. 15

FIG. 16

Part No. 124301: 4 Pin (M12) Female Field
Wireable Connector for 6-8 mm Cable

FIG. 17

20 332305J

Part No. 124594: 4 Pin (M12) Male Field
Wireable Connector for 6-8 mm Cable

FIG. 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

Installation

FIG. 19

NOTE: Field wireable connectors are for sensors with

integrated cable.

332305J 21

Setup

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 dispensing 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
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 allevi­ate unintended pressure rises in the system and pro­tect the G3 pump from damage.

IG. 20 for an exam-

• Only use a pressure relief valve that is rated for
no more than the working pressure of any com­ponent installed in the system. See Technical
Data, page 81.

• 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

22 332305J

Setting Pump Outlet Volume

D

NOTE:

• Before making any adjustments to pump volume,
Relieve Pressure following procedure on page 22.

• Only use Graco supplied spacers to control output
volume.

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

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

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

IG. 21).

Setup

FIG. 21

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.

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

Output Volume / Minute

No. Spacers

20.122

10.183

00.254

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.

cubic inches cubic cm

• 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 inlet fitting (D) (FIG. 22) 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. 24).

NOTICE

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

332305J 23

F

IG. 22

Setup

D

E

max fill
line

vent hole

Models without a follower plate:

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

IG. 23

F

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

To start the pump press the manual run
button.

Models with a follower plate:

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

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

To start the pump press the manual run
button.

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

IG. 25) and

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

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

F

IG. 24

4. Remove fill hose.

FIG. 25

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

be used as an overfill port/indicator.

4. Remove fill hose.

Changing Greases

When changing greases, always use compatible fluids
or greases.

24 332305J

Auto-Fill Shut Off

pin

down

Setup

Loading 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 manufac­turer 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 pressur­ize and break the reservoir.

Changing Greases

When changing greases, always use compatible fluids
or greases.

The Auto-Fill Shut Off is used for refilling the G3 reser­voir in an automatic lubrication system. As fluid is added
to the reservoir, it pushes the plate valve up to the top of
the reservoir. The plate valve then pushes the valve pin
and closes the inlet fluid path.

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 sys­tem, be sure you know the maximum working pres­sure of each component. Never exceed the
maximum working pressure of the lowest rated com­ponent in the system. Over-pressurizing any compo­nent 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.

Remote Fill with Remote Fill Manifold

The reference letters used in the following instructions
refer to the Typical Installation diagram, 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 distributor.

When the fluid refilling path closes, the refilling line pres­surizes and brings the refilling pump to a pressurized
stall condition.

NOTE: The operator must monitor system while filling
the reservoir to prevent overfilling.

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 maxi­mum 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).

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

2. Verify the Auto-Fill Shut Off (B) pin is down, indicat­ing it is reset (F

FIG. 26

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

IG. 26).

332305J 25

Setup

pin
up

pin
up

4. Connect Supply Hose (J) between the Remote Fill­ing 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. 27,

• 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.

Remote Fill without Remote Fill Manifold

The reference letters used in the following instructions
refer to the Typical Installation diagram, 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 sta­tion 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 12.

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
pressure in the refill pump (F) builds and the pump
stalls.

IG. 28. The

FIG. 27

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 Mani­fold (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.

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

FIG. 28

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

5. Relieve remote filling station pump pressure using
the following Remote Filling Station Pressure Relief
procedure:

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

26 332305J

Setup

Y

L

W

a

b

Remote Filling Station Pressure Relief

The reference letters used in the following instructions
refer to the Typical Installation diagrams starting on
page 10.

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.

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.

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.

• Do not overfill (F

• Do not operate G3 without reservoir attached.

• Only use oils with viscosity at least 40 cSt.

IG. 30).

a. To relieve pressure between the Refill Pump (F)

and Auto-Fill Shut Off (B), open ball valve (bv)
(F

IG. 29). Pressure will be released and excess

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

FIG. 29:

b. Close supply hose pressure relief valve (Y)

when all pressure has been relieved.

FIG. 30

1. Remove fill cap (a).

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

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

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

332305J 27

Setup

Priming

NOTE: It is not necessary to prime pump every time

pump is filled with lubricant.

Pump only requires priming the first time it is used or if it
is allowed to run dry.

1. Loosen pump element fitting (F

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

IG. 31).

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

IG. 32).

FIG. 32

F

IG. 31

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

IG. 31).

28 332305J

Quick Setup Guide

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Quick Setup Guide

332305J 29

Max Model Setup

DISPLAY

• A blinking LED under HH, MM, SS

or ## identifies type of measurement
unit you are setting; i.e., HH is
hours.

• A blinking number on the display

indicates the G3 is in SETUP
MODE.

• In RUN MODE displayed numbers

count up or down. See Time ON and
Time OFF.

ON TIME/BACKUP TIME

• LED lights when ON

Time/Backup Time is running.

• Display shows time as MM:SS

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

• Sets the limits for the amount

of time to complete a cycle or
build up pressure before a
warning is activated.

• Counts down from a set time to

zero.

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 indi-

cating PIN is required to
enter setup.

• In SETUP MODE LED

lights when setting up the
PIN.

PRELUBE

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

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.

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.

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.

MACHINE COUNT

• LED lights when Machine Count

is used to control Pump OFF
function.

• Counts independent machine

operations with a sensor to con­trol Pump Off duration.

• Time OFF function can be used

as a backup for Machine Count.

Max Model Setup

Control Panel Overview (FIG. 33)

NOTE: Programming instructions begin on page 31.

IG. 33

F

30 332305J

Max Model Setup

Programming the Max Model

Checking 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 connec­tion.

This creates a power cycle and the firmware version
displays on the screen during the first few seconds
of power up. See F

IG. 34.

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

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

Entering Setup Mode

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

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

FIG. 34

Powering Units With Controllers

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

NOTE:

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

Entering a PIN Code to Access Setup Mode

The G3 controller does not require a user to provide a
PIN code to access the programming features of the
unit. However, Graco understands that some users may
want to protect the programming settings and therefore,
an option for adding PIN Code authorization is available.
The instructions for setting up PIN Code Authorization
are provided in the Advanced Programming section of
this manual. See page 50.

To enter the PIN Code:

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

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

3. The cursor is automatically
positioned to enter the first
character of the PIN Code.
Use the UP and DOWN
ARROW buttons to move up

332305J 31

Max Model Setup

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.

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.

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.

Setting the Real Time Clock

DMS™ Equipped Models Only

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

Enter the Year:

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

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

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 pro­gram the first digit of the
date.

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

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

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

32 332305J

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

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

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

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

Max Model Setup

or

4. Press the ENTER button to set the
date.

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

Enter the Time:

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

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

• The LED under the
HH lights when set­ting hours and the
LED under the MM
lights when setting
minutes.

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

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

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

2. Press the ENTER button to set the
number.

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

4. Press the ENTER button to set the
number.

5. The next number field to the right blinks and the
LED under the MM lights indicating the G3 is ready
to program the minutes fields.

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

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

Programming ON Duration

• OFF, C1 (C2, C3) or
P1 (P2, P3) displays,
identifying the func­tion you are program­ming.

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

• C1, C2, C3 - Completing a specific number of

cycles measured by an external prox/cycle
switch

• P1, P2, P3 - Reaching a specific pressure

threshold measured by an external pressure
switch - OR,

• OFF - A specific duration of time elapses.

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

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

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

NOTE: Field cannot be left blank. If C / P2 and C /
P3 are not used, OFF must be entered instead.

Cycle (C1, C2, C3) Setup

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

NOTE:

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

1. Use UP or DOWN arrow but­ton to toggle display between
OFF / C1 / P1 on the display.

2. When C1 is
on display,
press the
ENTER
button to
save selec­tion and begin programming Cycle data.

332305J 33

Max Model Setup

• The first number
displayed after the
“C1” on the dis­play blinks, indi­cating the device
is ready to pro­gram the number of C1 cycles.

• The LED under the
# sign lights when
setting the number
of cycles.

3. Program the number of
cycles by pressing the UP or
DOWN ARROW button to
move up or down through
number 0-9.

4. The cycle field is a 2 digit number. When
the correct first numeral of the number
displays, press the ENTER button to
save the number. The cursor automati­cally moves to the second number field.

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

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

Pressure Control (P1, P2, P3) Setup

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

• Pressure control is an ON / OFF selection only.

1. Use the UP or DOWN arrow
button to toggle between OFF
/ C1/ P1.

2. When P1
displays,
press
ENTER
button to
save
selection.

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

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

NOTE: If C / P2 and C / P3 are not used, the default
OFF setting must be entered instead.

6. After you set the last field and press the
ENTER button, the G3 saves the Cycle
information and moves to setting
Backup Time, page 37.

If P1 / P2 / P3 is selected the vent valve time is auto­matically set to 5 minutes. If the unit is used in an
injector based system and a sensor input is not
used, the user must update the vent valve time in
advanced programming. (See Advanced Program­ming, A-3 Vent Valve Time, page 51.)

Input Not Used

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

1. Use UP or DOWN arrow but­ton to toggle between OFF /
C1 / P1 on the display.

2. When
OFF is on
the dis-

34 332305J

Max Model Setup

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 typi­cal cycle and double that value (to a maximum of 30
minutes).

Programming 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 (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.

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.

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).

332305J 35

Max Model Setup

OR

• 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
be 0 or exceed 30 minutes. If a value
of 0 or a value greater than 30 min‐
utes 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.

.

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

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

The G3 automatically switches to the OFF Time
SETUP MODE.

PUMP OFF / REST Setup

After setting the parameters for either Cycle (C1, C2 or
C3) or Pressure (P1, P2, or P3) ON modes, the OFF or
pump rest cycle must be set up. There are 3 ways to
control this function:

• Machine Count switch activation, or

• Machine Count activations limited by a 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. 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.

36 332305J

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

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

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

NOTE: After the Machine Count value is entered, the G3
can be programmed to backup the machine count input
with time.

Max Model Setup

OR

Backup Time Setup

1. The OFF Time LED lights.

OFF displays.

2. Press the UP or
DOWN ARROW but­ton to change OFF to
RUN or FLT on the
display.

• RUN: After

backup time
expires the pump
automatically
goes into an ON
cycle and shows
a machine count
warning.

• FLT: After

backup time
expires, the
pump automati­cally 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.

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

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

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

Programming Backup Time

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

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

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

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

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

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

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

332305J 37

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.

Max Model Setup

OR

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

7. After selecting ON, refer to page 34.

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

OFF Time

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

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

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

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

• 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 num-

ber 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 informa­tion is saved.

Prelube

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

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

ON - The unit begins a pump cycle.

Setting Prelube

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

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

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

3. Press the ENTER button to set the
selection.

38 332305J

Max Model Setup

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

Prelube Delay

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

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

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

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

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

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

DMS™ Models Only

Downloading Data

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

NOTE: The G3 pump stops pumping as soon as the
USB flash drive is plugged into it.

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

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

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

5. G3 pump restarts cycle in the OFF mode.

6. Remove the USB flash drive.

Storing Pump Program Settings
to the Flash Drive

The pump program settings file is named 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. Modification
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.

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.

332305J 39

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

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

5. G3 pump restarts cycle in the OFF mode.

6. After the download is com­plete, press and hold the UP
and DOWN ARROW button

Max Model Setup

for 3 seconds to store the current setup to the USB
flash drive.

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

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

9. G3 pump restarts cycle in the OFF mode.

10. Remove the USB flash drive.

Uploading Pump Program
Settings to the Pump

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

NOTE:

• The USB flash drive must contain file

GRACO/G3Config/g3config.bin (for 0209 and
earlier) or GRACO/Config/config.bin (for 0706
or later).

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

9. G3 pump restarts cycle in the OFF mode.

10. Remove the USB flash drive.

11. After the USB flash drive is
removed, press and hold the
UP and DOWN ARROW but­tons for 3 seconds to enter
the SETUP MODE (see
Entering Setup Mode, page 31).

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

32).

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

Viewing the UNIT DMS ID Number

1. In RUN mode, press and hold the
DOWN ARROW button.

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 restarts cycle in the OFF mode.

6. After the download is com­plete, press and hold the
RESET button and UP
ARROW button for 3 seconds
to upload the setup stored in the USB flash drive.

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.

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

40 332305J

Operation / Data Log

Operation / Data Log

During operation the G3 Pump stores information as
Log and Summary Files.

Logs contain the following information:

• Log Name

•DMS ID Number

• Current Software Graco Part Number

• Current Software Version

• Date and Time of Upload

System Event Log

The System Event Log lists the date and time of the last
800 common system events such as pump cycles, man­ual run and setting changes. The most recent event is
listed first.

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

Sample System Event Log

Example Event Log 1: Pump cycle of a divider valve

system with a proximity switch set to detect 5 divider
valve cycles.

G3 System Event Log
DMS ID Number: 0025 (see page 40)

Software Part Number: 16F821
Software Version: 1019

09/29/2010 14:1400

Date Time Description
9/29/2010 14:13:02 Pump Run Off
9/29/2010 14:13:02 C1 Cycle Completed
9/29/2010 14:12:39 C1 Cycle Detected
9/29/2010 14:12:34 C1 Cycle Detected
9/29/2010 14:12:28 C1 Cycle Detected
9/29/2010 14:12:23 C1 Cycle Detected
9/29/2010 14:12:17 Pump Run On

The folder structure is as follows:

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

Example: GRACO/G3_00025/20100911/EVENT­LOG.CSV.

332305J 41

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 The pump entered an on cycle and is

operating and dispensing material.

Pump Run Off The pump entered an off cycle and is

not dispensing.

Pump Run Can­celed

G3 Power On The pump powered on.

G3 Power Off The pump powered off.

Program Variable
Change

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

C2 Cycle Detected

C3 Cycle Detected

C1 Cycle Com­pleted

C2 Cycle Com­pleted

C3 Cycle Com­pleted

P1 Pressure Com­pleted

P2 Pressure Com­pleted

P3 Pressure Com­pleted

Machine Count
Completed

Local Manual Run
Initiated

Remote Manual
Run Initiated

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

The setup mode was entered.

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

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

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

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

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 Com­pleted

Successful Pin
Code Entry

Firmware Update
Completed

Lowe Power Fault
Pump On

Low Power Warn­ing Cleared

Low Power Fault
Cleared

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

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

The firmware was updated.

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 threshold.
The warning was cleared either by user
intervention, or by self-correction.

The voltage of the power source
dropped below and acceptable thresh­old 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/G3_{DMS_id}/{download date - YYYYm­mDD}/ERRORLOG.CSV

Example: GRACO/G3_00025/20100911/ERROR­LOG.CSV.

42 332305J

Operation / Data Log

Sample Error Log

G3 Error Log
DMS ID Number: 00025 (see page 40)
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 An internal software error

occurred. Contact Graco Cus­tomer Service.

Low Level Warning The unit entered a low level

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

Low Level Fault The alarm time in low level

warning has elapsed. The unit
will not pump until the reservoir
is filled and the fault is cleared.

Cycle 1 Not Detected In a divider valve system, the

Cycle 2 Not Detected

Cycle 3 Not Detected

Pressure 1 Not
Detected

Pressure 2 Not
Detected

Pressure 3 Not
Detected

system has not received the
programmed number of divider
valve cycles for the specified
input in the programmed
backup time.

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

System Already Pres­surized 1

System Already Pres­surized 2

System Already Pres­surized 3

Machine Count Sensor
Failure

Motor Overcurrent The unit is out of expected

High Temperature
Warning

Low Temperature
Warning

USB Unable to Mount The USB flash drive that was

USB Unsupported
Device

USB File Not Found The pump program setting file

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

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

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

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

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

installed was unable to connect
and communicate with the
pump.

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

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

332305J 43

Operation / Data Log

USB Folder Navigation The pump program setting file

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

USB Invalid File The pump program 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.

44 332305J

Functional Summary

(see page 40)

Operation / Data Log

The Functional Summary contains two types of data.

• The first report type, labeled User under the Type
heading in the first column of the Sample Functional
Summary, only provides data compiled since the
last time the Functional Summary was reset through
present day (see A6 - Clearing the Functional and
Technical User Summary, page 53).

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

Sample Functional Summary

• The second report type, labeled Factory under the
Type heading in the first column of the Sample
Functional Summary, covers the cumulative life of
the pump from the first day it was put into service
through present day.

This is very similar to an odometer in your car.

The log file is stored as:

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

Example: GRACO/G3_00025/20100911/FUNC­SUM.CSV

332305J 45

Operation / Data Log

Common Functional Summary Data entries are listed
below.

Number of Cycles The number of lubrication cycles

the unit has started.

Total Run Hours 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 The number of times the remote

manual run button was pressed.

Average Run Time The average amount of time per

lubrication cycle that the pump
has been running (MM:SS).

Average Cycle 1 Time The average amount of time the

Average Cycle 2 Time

Average Cycle 3 Time

Average Duty Cycle The average percentage of time

Max Duty Cycle The highest percentage of time

Total Low Level Faults Total number of low level faults.

Total Cycle Pressure
Faults

Total Other Faults Faults other than low level or

Total Fault Hours Number of hours the system has

Total Low Level Warnings Number of low level warning

Total Cycle Pressure
Warnings

Total Other Warnings All other warnings including tem-

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

the unit has been pumping while
it has been powered on.

for one lubrication cycle that the
unit has been pumping while it
has been powered on.

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

sensor feedback.

been powered on in fault mode.

conditions.

Total number of warning condi­tions related to sensor feedback.
This is only applicable if fault
retries are used.

perature and motor current.

46 332305J

Operation / Data Log

Technical Summary

The Technical Summary contains two types of data.

• The first report only provides data compiled since
the Pump Summary was reset to present day (see
A6 - Clearing the Functional and Technical User
Summary).

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

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

This is very similar to an odometer in your car.

The log file is stored as:

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

Sample Technical Summary

Example: GRACO/G3_00025/20100911/TECH­SUM.CSV

Common Technical Summary Data entries are listed
below.

Average Input Board
Voltage (DC)

Peak Input Board Voltage
(DC)

Average Motor Current The average motor current mea-

Peak Motor Current The peak motor current mea-

Average Internal Tem­perature

Peak Internal Tempera­ture

Low Internal Tempera­ture

The average input voltage mea­sured by the internal circuit board.

The peak input voltage measured
by the internal circuit board.

sured by the unit.

sured by the unit.

The average internal temperature
seen by the unit.

The peak internal temperature
seen by the unit.

The lowest internal temperature
seen by the unit.

G3 Technical Summary
DMS ID Number: 00025 (see page 40)
Software Part Number:16F821
Software Version: 0205
12/27/20109:50:51

Latest Values
Temp Voltage
31C 23.877

Type Start Date Average

Board
Voltage

Peak
Board
Voltage

Average
Motor
Current

Peak
Motor
Current

Average
Internal
Temp

Peak
Internal
Temp

Low
Internal
Temp

User 12/21/201023.877 23.877 0.062 0.062 30C 35C 28C

Factory 9/30/2010 22.804 23.877 1.091 0.362 33C 42C -10C

332305J 47

Advanced Programming

Advanced Programming

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

Advanced

Option

A1 Max Lockout

A2 Max Low Level Alarm

A3 Max Vent Valve Time MM:SS (minutes:seconds) sets

A4 Max Alarm Retry Sets number of automatic

A5 Max Active Alarm Changes alarm output behav-

Model Setting Format/ Description Why Use This?

Secures setup modes with PIN Prevents unauthorized users to adjusting set-

Code (Optional)

MM:SS (minutes:seconds) sets

Time

amount of time between Low
Level Warning to Low Level
Fault.
Default = 3 minutes

amount of time vent valve stays
open after Pump ON Mode.

Default = 5 minutes

retries after a Cycle or Pressure
Alarm.

Default = 0

ior.

Default = OFF

tings.
To accommodate most lubrication situations, a

conservative amount of time is programmed
between the low level warning and fault to help
protect unit from running dry. If necessary the
amount of time the unit runs before stopping due
to a low level fault can be adjusted.

• In an injector based system that does not use

a sensor for feedback, determines the amount
of time the system vents.

• Vent time can be modified.

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

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

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

™

A6

A7 Max Constant Alarm

DMS

Equipped

Models

Functional and
Technical User
Summary Reset

Output on Fault

Firmware 6.02 and later

A8 Max 4 Digit Hour Off

Time

A9 Max

and

“08” option

Toggle Low Level
Output on Warning
or Fault

Clears the Functional and Tech­nical User Summaries

Changes alarm output behav­ior.

Default = OFF

Changes maximum OFF time.

Default = OFF

Changes Low Level Indication
behavior.

Default = OFF

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.

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

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.

48 332305J

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

Advanced Programming

A10 Max Low Level Reset

Upon Power ON

A11 Max Warning OFF

through alarm relay

Changes low level fault upon
power ON.

Default = OFF
Changes alarm output behav-

ior.

Default = OFF

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.

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

A12 Max Prelube Sequences Changes the number of the

Prelube sequences.

Default = 0001

A13 Max MM:SS Off Time Changes the OFF time pro-

gramming from HH:MM to
MM:SS

Default = OFF

Entering a PIN Code for the First Time

5. Press the ENTER button to set the num-

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

This function changes the programming of the
OFF time.

ber. The cursor automatically moves to

A1 - Setting Up PIN Code

the next number field.

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.

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.

332305J 49

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.

Selecting Advanced Setup Options

1. Press the UP or DOWN
ARROW button to move up or
down through Advanced
Options A1 - A7.

2. Press the ENTER button to set the
selection.

50 332305J

Advanced Programming

A2 - Low Level Alarm Time

Pump ON mode only.

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

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

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

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.

F

IG. 35

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 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.

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 38). 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.

332305J 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, indi­cating the Vent Valve Time is being
programmed.

• 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.

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

Unit exits Advanced Programming.

A4 - Alarm Retry

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

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

• When programming a time of less then 10 minutes
you must program a leading zero in the first number
field and press the ENTER button to save the zero
selection.

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

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

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

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

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

FIG. 36

To set the Alarm Retry:

1. The default value
0000 appears in the
display.

2. Press the UP or DOWN
ARROW button to move up or
down through number 0-9.

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

52 332305J

Advanced Programming

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.

3. Press the ENTER button to exit
Advanced Programming.

A6 - Clearing the Functional and Technical
User Summary (DMS

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

™

Models only)

F

IG. 37

1. The default OFF dis­plays.

2. Press the UP or DOWN
ARROW button to change
OFF to ON on the display to
activate alarm condition.

FIG. 38

1. Press the UP or DOWN
ARROW button to move
through Advanced Options
until Advanced Option A6 is
displayed.

2. Press the ENTER button.

3. “Data” displays.

4. Press the RESET but­ton. “Reset” displays.
The summary data is
cleared.

5. Press the RESET or
ENTER button to exit.

332305J 53

Advanced Programming

ON

OFF

!

1 23

HH MM

SS ##

MM : SS HH : MM

2

3

1

P

C

C
P

C
P

C
P

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.

F

IG. 39

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.

FIG. 40

1. The default OFF dis­plays.

2. Press the UP or DOWN
ARROW button to change
OFF to ON on the display to
activate alarm condition.

3. Press the ENTER button to exit
Advanced Programming.

54 332305J

Advanced Programming

A9 - Toggle Low Level Output on Low Level
Warning or Fault

This function changes the behavior of the low level out­put 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 continue. If a low
level condition exists during the 5 revolutions, it will go
into a low level fault.

Low Level ON LED illuminates (F

IG. 42).

F

IG. 41

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.

FIG. 42

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.

332305J 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 func­tion to add more lubrication sequences upon pump start
up. While running multiple sequences, after the initial
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. 42)

F

IG. 43

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 332305J

FIG. 44

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.

NOTE: When prelube is on, and the pump is pow­ered-up, the pump will run this amount of lubrication
ON sequences.

3. Press the ENTER button to exit
Advanced Programming after the last
digit of the prelube sequence is dis­played.

A13- MM:SS OFF Time

This function changes the programming of the OFF
Time.

OFF and Warning LEDs Illuminate

Advanced Programming

2. Press the UP or DOWN
ARROW to change OFF to
ON on the display. The
OFF/Backup Time in setup
mode will be displayed in
MM:SS (Minutes/Seconds).

3. Press the ENTER button to exit
Advanced Programming.

F

IG. 45

1. The default OFF is
displayed.
OFF/Backup time in
setup mode is dis­played in HH:MM
(Hours/Minutes).

332305J 57

Run Mode

ON

OFF

!

1 23

HH MM

SS ##

MM : SS HH : MM

2

3

1

P

C

C
P

C
P

C
P

ON

OFF

!

1 23

HH MM

SS ##

MM : SS HH : MM

2

3

1

P

C

C
P

C
P

C
P

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.)

IG. 46).

• The example shown in F

IG. 46 shows an OFF Time

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

FIG. 47

• When the ON Time count reaches zero, the pump
shuts off again and the system again runs OFF
Time cycle and the OFF Time LED is now again illu­minated (F

IG. 46).

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.

IG. 46

• 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
8 minutes and 42 seconds before the lubrication
cycle ends.

58 332305J

IG. 47 shows an ON Time of

IG. 47).

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).

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

F

Lubrication Mode (Pump ON) Controls

Run Mode

ON

OFF

!

1 23

HH MM

SS ##

MM : SS HH : MM

2

3

1

P

C

C
P

C
P

C
P

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

48).

The example shown in F

IG. 48 shows sensor C1

with 5 cycles remaining.

IG.

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. 49 and FIG. 50).

• 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. 49 shows sensor P1

with a pressure switch that has been triggered.

F

IG. 50 (page 60) shows sensor P2 with a pres-

sure switch that has NOT been triggered.

HH MM

SS ##

!

IG. 48

F

ON

OFF

MM : SS HH : MM

C

1

P

C

C

2

P

C

P

3

P

1 23

FIG. 49

332305J 59

Run Mode

ON

OFF

!

1 23

HH MM

SS ##

MM : SS HH : MM

2

3

1

P

C

C
P

C
P

C
P

ON

OFF

!

1 23

HH MM

SS ##

MM : SS HH : MM

2

3

1

P

C

C
P

C
P

C
P

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.

F

IG. 50

The example shown in F

IG. 51 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).

FIG. 51

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.

60 332305J

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.

Run Mode

ON

OFF

!

1 23

HH MM

SS ##

MM : SS HH : MM

2

3

1

P

C

C
P

C
P

C
P

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. 52).

• The display indicates the number of machine
counts remaining.

The example shown in F

IG. 52 shows the

remaining number of machine counts is 0045.

Backup Time

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

• The LED next to 1-2-3 illuminates (F

IG. 53).

• The display shows the amount of time remain­ing till a fault or lubrication mode (pump ON).

The example shown in F

IG. 53 shows 4 hours

and 17 minutes remaining until a fault or lubrica­tion 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 HH : MM

OFF

F

IG. 52

C

1

P

C

C

2

P

C

P

3

P

1 23

FIG. 53

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).

332305J 61

Run Mode

ON

OFF

!

1 23

HH MM

SS ##

MM : SS HH : MM

2

3

1

P

C

C
P

C
P

C
P

Additional Controls

Venting

In Max models a Vent Time can be set using the
Advanced Programming mode (page 51). This is typi­cally done in a Pressure Based System (P1) to allow
injectors to reset.

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

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

• If Machine Count is set, the display will alternate
between machine counts remaining and backup
time (Max Model Rest Mode, page 60).

• If Machine Count has been set the LED next to
1-2-3 illuminates (F

• If Machine Count has not been set the display
shows OFF Time (See Time Control, page 58).

• If Machine Count has not been set the LED next
to the clock in the OFF field illuminates (See
Time Control, page 58).

IG. 52, page 61).

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

• The Prelube LED lights (F

IG. 54).

IG. 54).

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

IG. 54

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

• While unit is venting, VEnt will display and alter­nate with Machine Count and the Backup Time
or the OFF Time.

Prelube / Prelube Delay

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

Prelube

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

• Power to the unit cycles OFF then ON.

• Unit immediately begins a lubrication cycle.

• Max Model - display shows Cycle/Pres­sure/Backup Time (See Max Model Lubrication
Mode Controls, page 58).

Prelube Delay

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

FIG. 54

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.

• Power to the unit cycles OFF then ON.

• Unit immediately begins the Prelube Delay

62 332305J

count down until the lubrication cycle begins.

Alarms: Firmware Versions 6.01 and Below

ON

OFF

!

1 23

HH MM

SS ##

MM : SS HH : MM

2

3

1

P

C

C
P

C
P

C
P

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 What it Looks Like What it Indicates Solution

Low Level
Warning

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

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

Add lubricant to reservoir.

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

332305J 63

Alarms: Firmware Versions 6.01 and Below

ON

OFF

!

1 23

HH MM

SS ##

MM : SS HH : MM

2

3

1

P

C

C
P

C
P

C
P

ON

OFF

!

1 23

HH MM

SS ##

MM : SS HH : MM

2

3

1

P

C

C
P

C
P

C
P

Low Level
Fault

Cycle /
Pressure
Warning

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

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

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

Add lubricant to reservoir.

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

If repriming pump is
required, the low level
alarm time should be
decreased. See A-2:
Advanced Programming,
Low Level Alarm Time
page 51.

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

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

Press the
RESET but­ton to clear

warning.
(see Advanced Program­ming, page 48).

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

64 332305J

Alarms: Firmware Versions 6.01 and Below

Cycle /
Pressure
Fault

Machine
Count Fault

HH MM

ON

MM : SS HH : MM

C

1

P

C

2

P

C

3

P

HH MM

ON

MM : SS HH : MM

C

1

P

C

2

P

C

3

P

SS ##

OFF

C

P

C

P

1 23

SS ##

OFF

1 23

In pressure mode indi­cates that unit is over pres-

!

surized or a lubrication
cycle was not completed in
the user-defined amount of

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

time.

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

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.

332305J 65

Alarms: Firmware Versions 6.01 and Below

ON

OFF

!

1 23

HH MM

SS ##

MM : SS HH : MM

2

3

1

P

C

C
P

C
P

C
P

ON

OFF

!

1 23

HH MM

SS ##

MM : SS HH : MM

2

3

1

P

C

C
P

C
P

C
P

System
Fault

Motor Cur­rent Warn­ing

An internal fault has
occurred.

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

Contact Graco Customer
Service.

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

Examine pump to ensure
that it is rotating properly.

If necessary, contact
Graco Customer Service.

66 332305J

Alarms: Firmware Versions 6.01 and Below

Tempera­ture Warning

HH MM

SS ##

!

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

Use of the unit outside of

ON

MM : SS HH : MM

OFF

the recommended tem­perature range could cause
degraded system perfor­mance and possible dam-

C

1

P

C

C

2

P

C

P

3

P

1 23

age.

USB Error An error occurred during a

DMS operation.

HH MM

SS ##

!

ON

MM : SS HH : MM

OFF

Ensure the unit is used in

the correct operating envi-

ronment for the specific

temperature: -13° F to

158° F (-25° C to 70°C).

If necessary contact

Graco Customer Service.

Read the Troubleshooting

section of this manual

(page 75) for error num-

bers and fault descrip-

tions.

C

1

P

C

C

2

P

C

P

3

P

1 23

332305J 67

Alarms: Firmware Versions 6.02 and Above

ON

OFF

!

1 23

HH MM

SS ##

MM : SS HH : MM

2

3

1

P

C

C
P

C
P

C
P

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.

• 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

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

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

Add lubricant to reservoir.

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

68 332305J

Alarms: Firmware Versions 6.02 and Above

ON

OFF

!

1 23

HH MM

SS ##

MM : SS HH : MM

2

3

1

P

C

C
P

C
P

C
P

Low Level
Fault

Cycle Warn­ing

HH MM

ON

MM : SS HH : MM

C

1

P

C

2

P

C

3

P

SS ##

OFF

C

P

1 23

Level of lubricant in

Add lubricant to reservoir.
reservoir is low and addi­tional lubricant needs to be
added.

After lubri-

cant is

added press
Unit stops pumping and
displays amount of accu­mulated time since the

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 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 oper­ate for the number of lubri­cation cycles set by the
warning retry parameter
(see Advanced Program-

Press the

RESET but-

ton to clear

warning.
ming, page 48).

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

332305J 69

Alarms: Firmware Versions 6.02 and Above

ON

OFF

!

1 23

HH MM

SS ##

MM : SS HH : MM

2

3

1

P

C

C
P

C
P

C
P

ON

OFF

!

1 23

HH MM

SS ##

MM : SS HH : MM

2

3

1

P

C

C
P

C
P

C
P

Pressure
Warning

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

Unit will continue to oper­ate for the number of lubri­cation cycles set by the
warning retry parameter
(see Advanced Program­ming, page 48).

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

Cycle Fault In cycle mode indicates

that a cycle was not com­pleted 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 deter­mine if you have a
plugged or broken line or
other component failure,
i.e., divider valve, injector.

Press the
RESET but­ton to clear
warning.

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

Press and
hold the
RESET but­ton to clear
fault.

70 332305J

Alarms: Firmware Versions 6.02 and Above

Pressure
Fault

Machine
Count
Warning

HH MM

ON

MM : SS HH : MM

C

1

P

C

2

P

C

3

P

HH MM

ON

MM : SS HH : MM

C

1

P

C

2

P

C

3

P

SS ##

OFF

C

P

C

P

1 23

SS ##

OFF

1 23

In pressure mode indi­cates that unit is over pres-

!

surized or a lubrication
cycle was not completed in
the user-defined amount of

Examine system to deter-

mine if you have a

plugged or broken line or

other component failure,

i.e., divider valve, injector.
time.

Press and
LED corresponding to the
affected sensor input
blinks.

hold the

RESET but-

ton to clear

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

If the warning condition
clears itself on the next

!

automatic lubrication cycle,
the warning is cleared and
the unit continues normal

The unit has not received

the correct number of

machine counts in the

user defined Backup

Time.
operation.

Press and

hold the

RESET but-

ton to clear

warning.

332305J 71

Alarms: Firmware Versions 6.02 and Above

ON

OFF

!

1 23

HH MM

SS ##

MM : SS HH : MM

2

3

1

P

C

C
P

C
P

C
P

ON

OFF

!

1 23

HH MM

SS ##

MM : SS HH : MM

2

3

1

P

C

C
P

C
P

C
P

Machine
Count Fault

System
Fault

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

An internal fault has
occurred.

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

Press and
hold the
RESET but­ton to clear
fault.

Contact Graco Customer
Service.

72 332305J

Alarms: Firmware Versions 6.02 and Above

Motor
Current
Warning

Tempera­ture Warning

HH MM

ON

MM : SS HH : MM

C

1

P

C

2

P

C

3

P

HH MM

ON

MM : SS HH : MM

C

1

P

C

2

P

C

3

P

SS ##

OFF

C

P

C

P

1 23

SS ##

OFF

1 23

The measured motor cur­rent is above the recom-

!

mended operating
maximum value. Continued
use at excessive motor cur-

Examine system to make

sure it is operating cor-

rectly. A blocked line could

create excessive motor

current
rents could reduce life or
cause permanent damage.

Examine pump to ensure

that it is rotating properly.
Warning will self-clear any
time after 15 seconds On
Time start if the system

If necessary, contact

Graco Customer Service.
correction is made.

The internal temperature of
the unit is out of its recom-

!

mended operating range.

Use of the unit outside of

Ensure the unit is used in

the correct operating envi-

ronment for the specific

temperature: -13° F to

158° F (-25° C to 70°C).
the recommended tem­perature range could cause
degraded system perfor-

If necessary contact

Graco Customer Service.
mance and possible dam­age.

332305J 73

Alarms: Firmware Versions 6.02 and Above

ON

OFF

!

1 23

HH MM

SS ##

MM : SS HH : MM

2

3

1

P

C

C
P

C
P

C
P

USB Error An error occurred during a

DMS operation.

Read the Troubleshooting
section of this manual
(page 75) for error num­bers and fault descrip­tions.

74 332305J

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 What it Looks Like What it Indicates Solution

Low Power
Warning

HH MM

SS ##

If there is a voltage drop at
the power source during

!

operation, the pump will go
into a low power warning
condition.

Check voltage and avail-

able current output at the

power source of the

pump.

Low Power
Fault

ON

MM : SS HH : MM

C

1

P

C

C

2

P

C

P

3

P

HH MM

ON

MM : SS HH : MM

OFF

1 23

SS ##

OFF

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 contin­ues operation.

There is a low voltage con­dition 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.

C

1

P

C

C

2

P

C

P

3

P

1 23

332305J 75

Troubleshooting

Troubleshooting

Problem Cause Solution

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

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

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

Incorrect/loose wiring Refer to Installation instructions,

page 8.

Tripped external fuse due to internal
component failure

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

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

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

The ON Time was not entered cor­rectly

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.

Add grease following Loading Grease
instructions, page 23. Ensure air is
purged.

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

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

Refer to programming ON Time,
pages 33 and 58.

76 332305J

Problem Cause Solution

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

Display acts erratically

USB Error 00

USB Error 07

USB Error 11

USB Error 12

USB Error 13

Troubleshooting

Vent valve time needs to be config­ured

Faulty cycle/pressure wiring connec­tion to unit

Refer to Advanced Programming to
set ON Time, page 48.

Unplug cycle/pressure cables from
G3. Plug cables in one at a time to
identify the faulty connection.

Flash drive was removed during
operation

Flash drive unable to mount (initial­ize)

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

• Unplug the flash drive and
re-install.

• Cycle power and re-install the
flash drive.

• Retry using a different flash
drive.

• Verify format is FAT32 file sys­tem. 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 Ser­vice.

Pump program setting file not found Verify that the pump program setting

folder structure and file are stored
correctly on the flash drive. See Stor­ing Pump Program Settings to the
Flash Drive, page 39 for instructions.

Pump program settings directory not
found.

Verify that the pump program setting
folder structure and file are stored
correctly on the flash drive. See Stor­ing Pump Program Settings to the
Flash Drive, page 39 for instructions.

Bad pump program settings file The pump programs settings file is

corrupt. Restore file to the flash drive.
See Storing Pump Program Settings
to the Flash Drive, page 39 for
instructions.

Settings file is from different firmware
version

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 39 for instructions.

332305J 77

Troubleshooting

Problem Cause Solution

All other USB errors

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

• Unplug the flash drive and rein­stall.

• Cycle power and re-install the
flash drive.

• Retry using a different flash
drive.

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

78 332305J

Maintenance

Maintenance

Frequency Component Required Maintenance

Daily and at refill Zerk Fittings Keep all fittings clean using a clean

dry cloth. Dirt and/or debris can dam­age pump and/or lubrication system.

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

using a clean dry cloth.

Daily Display Keep display clean using a clean dry

cloth.

Monthly External Wiring Harness Verify external harnesses are secure.

332305J 79

Parts - 2 Liter Models

40a

44

14

1

42

13

18

17

34

36

33

37

41

21

30

15

4

3

31

Follower Plate Only

43

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

1

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

2

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

3

2

3

40b

3

45

35

27

23

16

60

57

Low Level Grease Models

Low Level

66

67

1

12

Oil Models

Parts - 2 Liter Models

80 332305J

Parts - 4 Liter and Larger Models

40a

44

35

14

1

41

13

18

17

34

16

36

33

37

42

21

30

15

4

3

31

Follower Plate Models

43

Torque to 4

1

Torque to 30

2

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

3

2

3

61

62

40b

3

27

1

45

60

23

57

Low Level Grease Models Only

67

66

Low Level Oil Models

12

13

Auto-Fill Shut Off Models

82

83

81

84

85

40c

87

88

74

36

89

45

73

72

Parts - 4 Liter and Larger Models

332305J 81

Parts

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

16

17

18 16F368

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

23 278136 PADDLE, low level 1

27 123025 SCREW, M6 1

30

258697 BOARD, circuit, Max, models 1

‡

‡ 262463

31 119228 SCREW, machine, flat head 2

33 16A579 LABEL, safety 1

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, included in
Kit 571044

PADDLE, stirring, 4 Liter models
and larger without follower plate

PADDLE, stirring, 2 Liter models
with follower plate, included in Kit
571045

PADDLE, stirring, 4Liter models
and larger with follower plate

PUMP, element, included in Kit
571041

SPACER, stroke adjust, included in
Kit 571041

™

BOARD, circuit, Max, DMS
models

Ref Part Description Qty

36 LABEL, brand 1

37 123741 FITTING, Zerk, grease 1

40a 24E984

1

2

1

1

1

1

1

2

1

40b 16G021

40a 24B702

40b 16G020

40c 17F484 RESERVOIR, 4 Liter, G3 AFSO 1

278139 SEAL, follower plate, 2 liter models 1

41

16F472 SEAL, follower plate, 4 liter models 2

42 PLATE, follower 1

43 ROD, follower plate 1

44 SPRING, compression 1

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

† 24E246 BAFFLE, low level, 4 liter models 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

57 117156 BEARING, sleeve 1

58 196548 LABEL 1

60 16D984 WASHER, low level models 2

61

RESERVOIR, 2 liter, grease,
included in Kit 571042, 571069

RESERVOIR, 2 liter, oil, included in
Kit 571179

RESERVOIR, 4 liter, grease,
included in Kit 571183

RESERVOIR, 4 Liter, oil, included
in kit 571182

RESERVOIR, mid-section (see quantity
by size / model below)

8 Liter models 1

12 Liter models 2

1

1

1

1

34 16A073 LABEL, overlay 1

WIPER, stirring, models without fol-

35

82 332305J

lower plate, included in Kit 571044
WIPER, stirring, models with fol-

lower plate, included in Kit 571045

1

1

62 ADAPTER, reservoir 1

66 126417 NUT, oil 1

67 24N806 FLOAT, oil 1

16 Liter models 3

Parts

a

ti15644

b

a = adjustment screw
b = locking nut

Ref Part Description Qty

72 PLATE, baffle, low level 1

73 SCREW, machine 2

74 SPRING, plate, valve, reset 1

81 VALVE, AFSO 1

82 BOLT, mounting 1

83 PACKING, o-ring 1

84 PACKING, o-ring 1

85 SEAL, upper, reservoir 1

87 SEAL, lower, reservoir 1

88 SPACER, seal, base 1

89 PLATE, valve 1

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

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

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

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

200

127783

127780

127781

127782

16U790 CABLE, DIN, bare) 1

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.

1

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

1

tomed out and there is at least 1/2 turn of adjustment
remaining. This is determined by turning the screw (a)

1

1/2 turn and then back turning it out again.

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

201

202

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

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

‡ Also order Ref 31, Part No. 119228 and Ref 34, Part
No. 16A073

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

332305J 83

124300

124333

124301

124594

124595

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

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

CONNECTOR, Eurofast, fem,
straight, 4Pin

CONNECTOR, Eurofast, 4 Pin

CONNECTOR, Eurofast, 5 Pin

Part Description Qty

1

VALVE, pressure relief, 500-3500 psi (3.44

1

16C807

1

563156

1

563157

1

563158

563159

563160

563161

563190

MPa, 34.4 bar - 24.1 MPa, 241 bar), Set pres­sure 3000 psi +
10%) Included in Kit 571028

VALVE, pressure relief, 750 psi (5.17 MPa,

51.71 bar)

VALVE, pressure relief, 1000 psi (6.89 MPa,

68.95 bar)

VALVE, pressure relief, 1500 psi (10.34 MPa,

103.42 bar)

VALVE, pressure relief, 2000 psi (13.78 MPa,

137.89 bar)

VALVE, pressure relief, 2500 psi (17.23 MPa,

172.36 bar)

VALVE, pressure relief, 3000 psi (20.68 MPa,

206.84 bar)

VALVE, pressure relief, 5500 psi (37.92 MPa,

379.21 bar)

10% (20.68 MPa, 206.8 bar +

1

1

1

1

1

1

1

1

Parts

Fuses

Part Description Qty

571039 FUSE, 12 volt DC

571040 FUSE, 24 volt DC

1

1

Installation and Repair Kits

Manual

Kit No. Description

571026 KIT, output union, 3 pump

571063 KIT, output union, 2 pump

571028

571071

571030 KIT, remote manual run, 12 volt DC

571031 KIT, remote manual run, 24 volt DC

571032

571033

571036 KIT, cover with “G” label NA

571041 KIT, pump element, includes Ref 17, 18, 33 3A0533

571042

571069

571044

571045

571046

571047

571058 KIT, output adapter, NPT

571070 KIT, output, adapter, BSPP

571060 KIT, fill, zerk, leak proof NA

571179

571183

127685 RING, fixing for CPC connector NA

16G02

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

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

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

KIT, remote manual run, 24 volt DC with
cable

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

KIT, repair, 2 liter reservoir, for models with
follower plate, includes Ref 13, 36, 40

KIT, replacement, paddle, 2 liter, for models
without follower plate, includes Ref 13, 16,
35, 57

KIT, replacement, paddle, 2 liter, for models
with follower plate, includes Ref 13, 16,
35,40a, 42, 57

KIT, replacement, paddle, 4-16 liter, for mod­els without follower plate, includes Ref 13,
16, 35, 57

KIT, replacement, paddle, 4 liter, for models
with follower plate, includes Ref 13, 16, 35,
57

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

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

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

CAP, filler 1

2

Number

3A0523

3A0525

3A0528

3A0534

3A0535

3A0522

3A0534571182

84 332305J

Technical Data

Technical Data

A

Pump Output Pressure 5100 psi (35.1 MPa, 351.6 bar)
Fill Inlet Pressure 5000 psi (34.4 MPa, 344.7 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

Outputs - Alarm Relay

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

Inductive: 0.2 A at 125 VAC, 1 A at 30 VDC
Max Operation Voltage Resistive: 250 VAC, 220 VAC

Inductive: 250 VAC, 220 VDC
Max Operating Current Resistive: 3 A (AC), 3A (DC)

Inductive: 1.5 A (AC), 1.5 A (DC)
Max Switching Capacity Resistive: 50 VA, 60 W

Inductive: 25 VA, 30 W
Min Permissible Load

Outputs - Vent Valve

Required Vent Valve Type Normally closed
Output Voltage

100/240 VAC 24 VDC
12 VDC Input Voltage

24 VDC Input Voltage
Max Operating Current 2 A
Max Operating Power 48 W

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

Required Switch Type Normally open (sink, source, or dry contact)
Sensor Voltage

100/240 VAC 24 VDC

12 VDC Input Voltage

24 VDC Input Voltage
Load Current

100/240 VAC 22mA @ 24 VDC

12 VDC 11mA @ 12 VDC

24 VDC 22mA @ 24 VDC
Maximum Residual Voltage

100/240 VAC 4 V

12 VDC 2 V

24 VDC 4 V
Maximum Off Current

100/240 VAC 1.5 mA

12 VDC 1 mA

24 VDC 1.5 mA
Input Impedance 1.1 K
Response Time 60 ms
Cycle Rate 8.0 Hz (50% duty cycle)

Resistive: 10
Inductive: 10

µA, 10m VDC
µA, 10m VDC

332305J 85

Technical Data

Fluid

Grease Models Grease NLGI 000 - #2

Oil Models At least 40 cSt oil.
Pumps Up to 3
Pump Output

0.12 in.

0.18 in.

0.25 in.

3

(2 cm3) / minute per outlet - 2 spacers

3

(3 cm3) / minute per outlet - 1 spacer

3

(4 cm3) / minute per outlet - 0 spacers
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
Sensor Inputs 3 (any of pressure or cycle)

1 (machine count)
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), amorphous polyamide, zinc plated steel,

carbon steel, alloy steel, stainless steel, nitrile rubber

(buna-N), bronze, nickel plated alnico, chemically lubri-

cated acetal, aluminum, PTFE
Sound Data <60 dB

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

Height Width Depth

Inches cm Inches cm Inches cm

86 332305J

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

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.

1.180 inch

30.0 mm

3.268 inch

83.0 mm

F

IG. 55

332305J 87

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: [phone] or Toll Free: 1-800-533-9655, Fax: [phone]

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

Copyright 2013, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

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

www.graco.com

October 2018