Graco G3-G-12NC-2L0000-00C00000 Instructions Manual Download Page 27

Page: 27 / 36

Troubleshooting

332291G

Troubleshooting

Problem

Cause

Solution

Unit does not power on

Incorrect/loose wiring

Refer to Installation instructions,
page 7.

Unit does not power on (DC models
only)

Tripped external fuse due to internal
component failure

Contact Graco Customer Service.

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

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

Replace fuse.

Unit does not power on (AC models
only)

Tripped internal power supply fuse
due to power supply failure

Contact Graco Customer Service.

Lubricant leaks past seal located on
the bottom of the reservoir

Reservoir retaining tabs are cracked
or broken

Replace reservoir.

Reservoir is being pressurized during
filling

Ensure vent hole is not plugged.

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

Unit not pumping during ON cycle,
but external controller functions

Failed motor

Replace unit.

Follower plate is not going down

Air is trapped in the reservoir
between the follower plate and lubri-
cant

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

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

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

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

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

Vent valve time needs to be config-
ured

Adjust external vent valve control
time.

After wiring and installing equipment,
pump is not working

Pump wired backwards

Rewire pump. See wiring and instal-
lation diagrams, page 13

Summary of Contents for G3-G-12NC-2L0000-00C00000

Page 1: ...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 Fill Inlet Pressure Important Safety Instructions Read all warnings and instructions in this manual Save these instructions Conforms to ANSI UL 73 Certified to CAN CSA Std 22 2 No 68 09 3132066 ...

Page 2: ...te Fill Manifold 10 Choosing an Installation Location 11 System Configuration and Wiring 12 Wiring and Installation Diagrams 13 Setup 18 Connecting to Auxiliary Fittings 18 Setting Pump Outlet Volume 19 Loading Grease 19 Auto Fill Shut Off 21 Filling Oil Unit 23 Priming 24 Pump Operation 25 Troubleshooting 27 Maintenance 28 Parts 2 Liter Models 29 Parts 4 Liter and Larger Models 30 Parts 31 Techni...

Page 3: ...000 0D000000 96G044 G3 G 12NC 4L0A00 L0C00000 96G048 G3 G 24NC 4L0A00 L0C00000 96G051 G3 A 24NC 4L0A00 L0C00000 96G053 G3 G 24NC 4LFA00 L0C00000 96G055 G3 G ACNC 4L0A00 LD000000 96G060 G3 A ACNC 4L0A00 LD000000 96G062 G3 G ACNC 4LFA00 LD000000 96G173 G3 G ACNC 4LFA00 0D00L000 96G179 G3 G ACNC 4LFA00 0D00L000 96G184 G3 G 24NC 4L0A00 0D00L000 96G210 G3 G 24NC 4LAA00 0D00L000 96G180 G3 G 24NC 4L0A02 ...

Page 4: ... A Oil Code aa Power Source 12 12 Volts DC 24 24 Volts DC AC 100 240 Volts AC Code bb Operation Control NC No Controller 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 A External Low Level 0 No Low Level monitoring Code ff Opti...

Page 5: ...d 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 r...

Page 6: ... CLEANING SOLVENT HAZARD Many solvents can degrade plastic parts and cause them to fail which could cause serious injury or property damage Use only compatible water based solvents to clean plastic structural or pressure containing parts See Technical Data in this and all other equipment instruction manuals Read fluid and solvent manufacturer s MSDSs and recommendations MOVING PARTS HAZARD Moving ...

Page 7: ...FIG 18 page 19 G Fuse DC models only Not included not shown Available from Graco See Parts page 32 H Power Sensor Panel both sides only one side shown I Part Number Model Number example only shown see page 4 Understanding the Model Number for details J Power Cord DIN shown K Follower Plate grease models only not available on all grease models L Vent Hole for Follower Plate grease models only not a...

Page 8: ... each out let user supplied See Parts page 32 C Supply Hose user supplied D Series progressive divider valves Divider Installations Injectors Injector Installations E To lube points F Proximity Switch Divider Installations Pressure switch Injector Installations G Vent valve Not included available from Graco See Parts page 33 H Return to reservoir FIG 3 FIG 4 A B D E F C A B D E F H G C ...

Page 9: ... 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 fil...

Page 10: ...es not stall dead head there is a leak in the system Key A G3 Pump B Auto Fill Shut Off Valve C Auto Fill Inlet D G3 Reservoir E Remote Fill Reservoir F Remote Fill Pump H Relief Valve J Supply Hose user supplied L Drain Tube L1 Option To reservoir L2 Option To overflow container S Pressure Regulator and Gauge U Pressure Relief Valve V Quick Disconnect W Overflow Container Y Supply Hose Pressure R...

Page 11: ... follower plate was installed on your pump See page 4 Understanding the Model Number to identify this character in your model number Use the three fasteners included to secure the G3 to the mounting surface Some installations may require an additional reservoir support bracket See Table below for bracket information AUTOMATIC SYSTEM ACTIVATION HAZARD If the system is equipped with has an automatic...

Page 12: ...ng Pump in Harsh Environments Use pump with CPC style power cable If using a DIN style power or alarm harness with a right angle mating connector make sure the con nector does not exit the unit in the UP direction Use a corrosion preventative electrical grease on all contacts The equipment must be grounded to reduce the risk of static sparking and electric shock Electric or static sparking can cau...

Page 13: ...llation diagrams for the cable included with the pump provided in this manual Power DIN AC 15 foot Pin and Related Wire Color FIG 7 Diagram Symbol Page Power DIN AC 13 Power DIN DC 14 Power CPC DC 14 Low Level Outputs 15 Pin Pin Name Color 1 Line Black 2 Neutral White 3 Not Used Not Used 4 Ground Green FIG 7 ...

Page 14: ...er CPC DC 15 foot Pin and Related Wire Color FIG 9 Pin Pin Name Color 1 VDC Black 2 VDC White 3 Not Used Not Used 4 Not Used Green FIG 8 Pin Pin Name Color 1 Not Used Not Used 2 VDC Black 3 VDC White 4 Not Used Not Used 5 Not Used Not Used 6 Not Used Not Used 7 Not Used Green FIG 9 ...

Page 15: ...r functional description See Technical Data page 34 for ratings Pins FIG 11 Pins FIG 12 Pin Pin Name Color 1 Not Used Not Used 2 VDC Black 3 VDC Red 4 LL N O White 5 LL COM Orange 6 Not Used Not Used 7 Not Used Green FIG 10 Pin Pin Name 1 Not Used 2 Not Used 3 LL N O 4 LL COM FIG 11 Pin Pin Name 1 LL N O 2 Not Used 3 LL COM 4 Not Used FIG 12 ...

Page 16: ...291G Part No 124333 Cable Pin Out M12 Wire Colors FIG 13 Part No 124300 Field Wireable Pin Out M12 Wire Colors FIG 14 Item No Color 1 Brown 2 White 3 Blue 4 Black FIG 13 Item No Color 1 Brown 2 White 3 Blue 4 Black FIG 14 ...

Page 17: ...Installation 332291G 17 Part No 124594 4 Pin Eurofast Male Field Wireable Connector FIG 15 Part No 124595 5 Pin Eurofast Male Field Wireable Connector FIG 16 FIG 15 FIG 16 ...

Page 18: ...leaning checking or servicing the equipment FIG 17 NOTICE Do not attach unsupported equipment to auxiliary fit tings such as fill ports and pump element Attaching unsupported equipment to these fitting can result in irreparable housing damage Always use two wrenches working in opposite directions when connecting anything to pump ele ment or auxiliary fittings See FIG 17 for an exam ple Torque pump...

Page 19: ...g on external conditions such as lubricant tem perature and back pressure from downstream connections Use of these volume adjustment in conjunction with setting the ON time of the pump will allow for control of the output volume Use these volume adjustments as a starting point and adjust as necessary to ensure desired lubrica tion dispense Loading Grease To ensure optimal performance from the G3 O...

Page 20: ...or higher viscosity fluids start pump to rotate stir ring paddle during fill to prevent air pockets from forming in grease Do not exceed 30 minutes run time For models using an external controller start pump operation per your controller specifications 3 Fill reservoir with grease until seal of follower plate breaches the vent hole FIG 20 and the majority of air is expelled from the reservoir NOTE...

Page 21: ...cal Graco distributor 1 Pull out and hold the Pressure Relief Knob T long enough to relieve line pressure between Fill Mani fold N and Auto Fill Shut Off Valve B 2 Verify the Auto Fill Shut Off B pin is down indicat ing it is reset FIG 21 NOTICE Care must be used when filling the reservoir using a pneumatic or electric transfer pump to not pressur ize and break the reservoir The remote filling sta...

Page 22: ...ellow Dust Cover over Fill Coupler M Remote Fill without Remote Fill Manifold The reference letters used in the following instructions refer to the Typical Installation diagrams starting on pages 8 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 fill...

Page 23: ...pply hose J from Quick Connect V Filling Oil Unit Only use oil appropriate for your application auto matic dispensing and the equipment s operating temperature Consult with machine and lube manu facturer for details The reservoir can be filled using a hand operated pump pneumatic pump or electric transfer pump Do not overfill FIG 25 Do not operate G3 without reservoir attached Only use oils with v...

Page 24: ...t is allowed to run dry 1 Loosen pump element fitting FIG 26 NOTE When loosening pump element fitting do NOT loosen pump element Loosening pump element will change the output volume 2 Only run pump until air free lubricant is dispensed out of element fitting FIG 27 3 Tighten pump element fitting using two wrenches working in opposite directions FIG 26 FIG 26 FIG 27 ...

Page 25: ... code location G or with a DIN connector in code location K See Understanding the Model Num ber page 4 The low level signal is monitored across PINS 3 and 4 For PIN 3 and 4 locations and wiring information the Low Level Outputs diagram page 15 NOTE A low level warning is triggered when the con troller detects PINS 3 and 4 have momentarily closed Grease Pumps When the grease level has reached a low...

Page 26: ...hat the fluid has reached a low level To ensure that a low level condition has been met the low level trigger must be detected for 10 continuous sec onds See FIG 29 for an illustration of a typical Low Level Out put response to low oil level Typical Low Level Output Response with Low Level Fluid in Oil Models FIG 29 Open Contact Position Closed ...

Page 27: ...re vent hole is not plugged If problem persists contact Graco Customer Service or your local Graco distributor for assistance Unit not pumping during ON cycle but external controller functions Failed motor Replace unit Follower plate is not going down Air is trapped in the reservoir between the follower plate and lubri cant Add grease following Loading Grease instructions page 19 Ensure air is pur...

Page 28: ...refill Fill Fittings Keep all fittings clean using a clean dry cloth Dirt and or debris can dam age pump and or lubrication system Daily G3 Pump Unit and Reservoir Keep pump unit and reservoir clean using a clean dry cloth Monthly External Wiring Harness Verify external harnesses are secure ...

Page 29: ...els 40a 44 14 1 42 13 18 17 36 33 37 41 21 15 4 3 Follower Plate Models 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 Oil Models 66 67 1 12 ...

Page 30: ...17 16 36 33 37 42 21 15 4 3 Follower Plate Models 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 61 62 40b 3 27 1 45 60 23 57 Low Level Grease Models 67 66 Low Level Oil Models 12 Auto Fill Shut Off Models 13 36 83 82 81 84 85 40c 87 88 74 89 45 73 72 ...

Page 31: ...uded in Kit 571045 1 36 LABEL brand 1 37 123741 FITTING zerk grease not included on oil models 1 40a 24E984 RESERVOIR 2 Liter grease included in Kit 571042 571069 1 40b 16G021 RESERVOIR 2 Liter oil included in Kit 571179 1 40a 24B702 RESERVOIR 4 Liter grease included in Kit 571183 1 40b 16G020 RESERVOIR 4 Liter oil included in kit 571182 1 40c 17F484 RESERVOIR 4 Liter G3 AFSO 1 41 278139 SEAL foll...

Page 32: ...t screw a clockwise increases pressure 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 1 200 127783 CABLE 15 ft 4 5 m SOOW w 7pos 3 pin 90 deg See Wiring Diagram page 14 1 16U790 CABLE DIN to flying leads See Wiring Diagram page 13 1 201 124300 CABLE M12...

Page 33: ...s without follower plate includes Ref 13 16 35 57 3A0535 571045 KIT replacement paddle 2 liter for models with follower plate includes Ref 13 16 35 40a 42 57 571046 KIT replacement paddle 4 16 liter for models without follower plate includes Ref 13 16 35 57 571047 KIT replacement paddle 4 liter for models with follower plate includes Ref 13 16 35 57 571058 KIT output adapter NPT 3A0522 571070 KIT ...

Page 34: ...e per outlet 2 spacers 0 18 in 3 3 cm3 minute per outlet 1 spacer 0 25 in 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 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...

Page 35: ... 1 or Option 2 See P N 126916 template FIG 30 0 367inch 9 3 mm 2x Ø 0 366 inch 9 3 mm 3 544 inch 90 0 mm 7 087 inch 180 0 mm 1 180 inch 30 0 mm 3 268 inch 83 0 mm 0 722 inch 18 3 mm 2x Ø 0 366 inch 9 3 mm 3 189 inch 81 0 mm 6 378 inch 162 0 mm 3 740 inch 95 0 mm 0 708 inch 18 0 mm Option 1 Option 2 ...

Page 36: ...close 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 ...

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