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
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