Graco G3 Series Instruction Manual Download Page 71

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Parts

332305B

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.

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

but as a protective

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

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

NOTE:

Turning adjustment screw (a) clockwise

increases pressure.

Fuses

Installation and Repair Kits

Part

Description

Qty

16C807



VALVE, pressure relief, 500-3500 psi (3.44
MPa, 34.4 bar - 24.1 MPa, 241 bar), Set
pressure 3000 psi + 10% (20.68 MPa, 206.8
bar + 10%) Included in Kit 571028

563156

VALVE, pressure relief, 750 psi (5.17 MPa,
51.71 bar)

563157

VALVE, pressure relief, 1000 psi (6.89 MPa,
68.95 bar)

563158

VALVE, pressure relief, 1500 psi (10.34 MPa,
103.42 bar)

563159

VALVE, pressure relief, 2000 psi (13.78 MPa,
137.89 bar)

563160

VALVE, pressure relief, 2500 psi (17.23 MPa,
172.36 bar)

563161

VALVE, pressure relief, 3000 psi (20.68 MPa,
206.84 bar)

563190

VALVE, pressure relief, 5500 psi (37.92 MPa,
379.21 bar)

ti15644

a = adjustment screw
b = locking nut

Part

Description

Qty

571039 FUSE, 12 volt DC

571040 FUSE, 24 volt DC

Kit No.

Description

Manual

Number

571026 KIT, output union, 3 pump

3A0523

571063 KIT, output union, 2 pump

571028

KIT, return to reservoir NPT, includes pres-
sure relief valve 16C807

3A0525

571071

KIT, return to reservoir BSPP, includes pres-
sure relief valve 16C807

571030 KIT, remote manual run, 12 volt DC

3A0528

571031 KIT, remote manual run, 24 volt DC

571032

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

571033

KIT, remote manual run, 24 volt DC with
cable

571036 KIT, cover with “G” label

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

3A0533

571042

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

3A0534

571069

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

571044

KIT, replacement, paddle, 2 liter, for models
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, output, adapter, BSPP
571060 KIT, fill, zerk, leakproof

571179

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

3A0534

571182

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

571183

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

Summary of Contents for G3 Series

Page 1: ...rofessional Use Only Not approved for use in explosive atmospheres or hazardous locations Part Nos page 3 5100 psi 35 1 MPa 351 6 bar Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this manual Save these instructions TI14705 Conforms to ANSI UL 73 Certified to CAN CSA Std 22 2 No 68 09 3132066 ...

Page 2: ...Grease 24 Filling Oil Unit 26 Priming 26 Quick Setup Guide 27 Max Model Setup 28 Control Panel Overview 28 Programming the Max Model 29 Pump OFF REST Setup 34 DMS Models Only 37 Operation Data Log 39 System Event Log 39 Error Log 40 Functional Summary 42 Technical Summary 44 Advanced Programming 45 Run Mode 51 Time Control 51 Alarms 57 Fault Warning Scenarios 57 Troubleshooting 62 Maintenance 64 P...

Page 3: ...4MX 2L0L00 1DMVA2R3 96G110 G3 G 24MX 2L0L00 UDMVA1R2 96G115 G3 G 24MX 2LFL00 UDMVA1R2 96G122 G3 A ACMX 2L0L00 1DMVA2R3 96G125 G3 G ACMX 2L0L00 UDMVA1R2 96G132 G3 G ACMX 2LFL00 UDMVA1R2 96G174 G3 A ACMX 2L0L00 UDMVA1R2 96G178 G3 G 24MX 2L0L00 0D00A100 Part Numbers 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...

Page 4: ...G3 G 24MX 8L0L00 10C00000 96G146 G3 G ACMX 8L0L00 1D000000 96G152 G3 G 12MX 8L0L05 10CV0000 96G154 G3 G 12MX 8L0L05 U0CV0100 96G156 G3 G 24MX 8L0L05 10CV0000 96G158 G3 G 24MX 8L0L05 U0CV0100 96G176 G3 A ACMX 8L0L00 UDMVA1R2 96G177 G3 G 24MX 8L0L05 00C0010M 96G186 G3 A 12MX 8L0L05 U0C0010M Part Numbers Model Numbers 96G105 G3 G 24MX 120L00 1DMVA2R3 96G120 G3 G ACMX 120L00 1DMVA2R3 96G164 G3 G 24MX ...

Page 5: ...olts 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 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 Code g h i j...

Page 6: ...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...

Page 7: ...S 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 8: ...ber example only shown see pages 5 Understanding the Model Number for details K Power Cord DIN shown 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 Models only The equipment must be grounded Grounding reduces the risk of electric shock by providing ...

Page 9: ... 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 F Proximity Switch Divider Installations Pressure switch Injector Installations G Vent valve Not included available from Graco See Parts beginning on page 67 H Return to reservoir A B C D E F A B...

Page 10: ...e you must use a model that includes a fol lower plate otherwise the G3 must be mounted upright Refer to your model number to confirm if a follower plate was installed on your pump See page 5 Understanding the Model 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 ...

Page 11: ...le identifies the correct fuse to use for your input voltage and the corresponding Graco Kit number Recommendations for Using Pump in Harsh Environments Use pump with CPC style power cable If using a DIN style power or alarm harness with a right angle mating connector make sure the con nector does not exit the unit in the UP direction Use a corrosion preventative electrical grease on all contacts ...

Page 12: ...wer cable Tri Color Remote Illumination via illuminated manual run input Unit in OFF Mode Deactivated off Off Off Unit in ON Mode Deactivated off On Green Warning Condition Activated on Toggles On and Off once per second Yellow Fault Condition Toggles On and Off once per second Toggles On and Off once per second Red Fault Condition Advanced Programming Setting A7 OFF Toggles On and Off once per se...

Page 13: ...owing Table identifies the wiring and installation diagrams provided in this manual Diagram Symbol Page Power DIN AC 14 Power DIN DC 15 Power CPC DC 16 Inputs M12 18 Vent Valve Outputs 19 Alarm Outputs 20 Illuminated Manual Run Input Kits 571030 571031 571032 571033 ...

Page 14: ...N AC 15 foot Part No 16U790 Pin and Related Wire Color FIG 3 Pin Pin Name Color 1 Line Black 2 NEUTRAL White 3 Not Used Not Used 4 GROUND Green FIG 3 4 2 1 1 2 3 4 Example Wiring Diagram Connector on Housing Connector on Cable 4 1 3 2 ...

Page 15: ...orrectly paddle could rotate counter clockwise which will damage the pump s internal components If this happens stop the pump immediately and wire unit correctly Pin Pin Name Color 1 VDC Black 2 VDC White 3 Not Used Not Used 4 Not Used Green FIG 4 Ignition Switch Fuse 1 2 3 4 Example Wiring Diagram Connector on Housing 12V pump 7 5A Graco kit 571039 24V pump 4A Graco kit 571040 4 2 1 Connector on ...

Page 16: ... 1 Not Used Not Used 2 VDC Black 3 VDC White 4 Not Used Not Used 5 Not Used Not Used 6 Not Used Not Used 7 Not Used Green FIG 5 1 2 3 4 5 6 7 Example Wiring Diagram Connector on Housing Connector on Cable Ignition Switch Fuse 1 2 3 4 5 6 7 12V pump 7 5A Graco kit 571039 24V pump 4A Graco kit 571040 1 3 2 7 6 5 4 ...

Page 17: ...available from Graco Contact your local Graco distributor or Graco Customer Service for additional information about these kits Pin and Related Wire Color FIG 6 Pin Pin Name Color 1 Not Used Not Used 2 VDC Black 3 VDC Red 4 LIGHT White 5 MANUAL ORANGE 6 Not Used Not Used 7 Not Used Green FIG 6 1 2 3 4 5 6 7 1 2 3 4 5 6 7 L Fuse 12V pump 7 5A Graco kit 571039 24V pump 4A Graco kit 571040 Example Wi...

Page 18: ...nputs M12 See Technical Data page 72 for rat ings FIG 7 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 out Connector on Housing ...

Page 19: ...Installation 332305B 19 Vent Valve Outputs See Technical Data page 72 for ratings FIG 8 1 2 3 1 Not Used 2 Relief 3 Relief 1 2 3 Example Wiring Diagram Pin out Connector on Housing ...

Page 20: ... example shown See Technical Data page 72 for ratings FIG 9 1 N O 2 N C 3 COM 4 Not Used 1 4 2 3 1 2 3 4 G3 Switch closes on alarm shown in non alarm position Alarm 9 30V 1 Amp Max 1 A Fuse Example Wiring Diagram Pin out Connector on Housing ...

Page 21: ... 332305B 21 Part No 124333 Cable Pin Out M12 Wire Colors Part No 124300 Field Wireable Pin Out M12 Wire Colors Item No Color 1 Brown 2 White 3 Blue 4 Black FIG 10 Item No Color 1 Brown 2 White 3 Blue 4 Black FIG 11 ...

Page 22: ...Installation 22 332305B Part No 124594 4 Pin Eurofast Field Wireable Connector Part No 124595 5 Pin Eurofast Field Wireable Connector FIG 12 FIG 13 ...

Page 23: ...re cleaning checking or servicing the equipment FIG 14 NOTICE Do not attach unsupported equipment to auxiliary fittings such as fill ports and pump element Attach ing 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 FIG 14 for an example Torque pu...

Page 24: ... 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 3 Tighten pump element fitting Torque fitting to 50 in lbs 5 6 N m Loading Grease To ensure optimal performance from the G3 Only use NLG...

Page 25: ... Models with a follower plate 1 Connect fill hose to inlet fitting FIG 16 2 For higher viscosity fluids start pump to rotate stir ring paddle during fill to prevent air pockets from forming in grease To start the pump press the manual run button 3 Fill reservoir with grease until seal of follower plate breaches the vent hole FIG 18 and the majority of air is expelled from the reservoir NOTE Vent p...

Page 26: ... Pour oil into reservoir to fill line b 3 Replace fill cap Hand tighten cap securely 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 FIG 20 NOTE When loosening pump element fitting do NOT loosen pump element Loosening pump element will change the...

Page 27: ...Quick Setup Guide 332305B 27 Quick Setup Guide 8 8 8 8 8 8 8 B 8 8 D 8 ...

Page 28: ...n cycle See page 57 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 indicat ing LED lights when Prelube function is enabled LEFT DIRECTION ARROW RESET In ADVANCED and SETUP MODES moves cursor in dis play one field to the left In RUN MODE s...

Page 29: ... Code to Access 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 prov...

Page 30: ...WN ARROW but tons to move up and down through the list of months until the current month is dis played in the field 2 Press the ENTER button to set the month The 2 digit date displays indicating the G3 is now ready to program the date Enter the 2 digit Date The first programmable character of the 2 digit date blinks indicating the device is ready to pro gram the first digit of the date The LED und...

Page 31: ...led 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 indicat ing which sensor of the pump control you are programming using either a specific number of cycles or by mon itoring a pressure switch C P2 ...

Page 32: ...or 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 sen sor input you will automatically be prompted to begin selecting pump control type for the next sen sor Repeat steps 1 2 to program P2 and P3 If P1 P2 P3 is selected...

Page 33: ... the second MM number field 4 Press the ENTER button to lock in the selection The next number field to the right flashes and the LED lights under SS indicating it is ready to program the seconds fields 5 Repeat steps 1 4 to set the SS seconds fields 6 After pressing the ENTER button to set the last SS field all the programmed ON Time information is saved The G3 automatically switches to the OFF Ti...

Page 34: ... 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 Notice the LED next to 123 on the G3 display lights indicating you are now in the Mac...

Page 35: ...r appears in the second HH number field 4 Press the ENTER button to lock in the selection The next number field to the right flashes and the LED lights under MM indicating it is ready to program the minutes fields 5 Repeat steps 1 4 to set the next MM minutes fields 6 After pressing the ENTER button to set the last MM field the OFF Time informa tion is saved 7 After selecting ON refer to page 32 N...

Page 36: ...ED next to the prelube icon on the G3 display lights indicat ing you are now in the Prelube setup mode 2 OFF displays If you want the prelube cycle to begin imme diately leave this set to OFF 3 Press the ENTER button to set the selection 4 If you want to set a prelube delay time press the DOWN ARROW button to change OFF to ON on the display Prelube Delay Prelube Delay can be entered to delay the s...

Page 37: ...oading 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 com plete press and hold the UP and DOWN ARROW button for 3 seconds to store the cur rent setup to the USB flash drive 7 data is displayed while the unit is downloading and storing the configu ration on...

Page 38: ...e page 29 12 In SETUP MODE set the YEAR MONTH DATE and TIME see Setting the Real Time Clock page 30 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 2 The Unit DMS ID number displays The unit continues to normal operation while the DMS ID is displayed 3 Release the DOWN...

Page 39: ...ultiple downloads are done on the same date the existing files will be writ ten over The folder structure is as follows GRACO G3_ DMS_id download date YYYYm mDD EVENTLOG CSV Example GRACO G3_00025 20100911 EVENT LOG CSV Sample System Event Log Example Event Log 1 Pump cycle of a divider valve system with a proximity switch set to detect 5 divider valve cycles G3 System Event Log DMS ID Number 0025...

Page 40: ...e C2 Cycle Com pleted C3 Cycle Com pleted P1 Pressure Com pleted The system is set up to monitor a pres sure 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 P2 Pressure Com pleted P3 Pressure Com pleted Machine Count Completed The system is set up to monitor a sen sor on the equipment being lu...

Page 41: ...e Motor Overcurrent The unit is out of expected motor current range Check the system to determine that it is functioning correctly i e no blocked lines Continued oper ation at excessive motor cur rents will cause degradation in pump life High Temperature Warning Internal temperature of the unit is above the designated oper ating Check the unit and sys tem to determine that it is functioning correc...

Page 42: ...nctional and Technical User Summary page 49 This is very similar to the resettable trip odometer in your car The second report type labeled Factory under the Type heading in the first column of the Sample Functional Summary covers the cumulative life of the pump from the first day it was put into service through present day This is very similar to an odometer in your car The log file is stored as ...

Page 43: ...der valve systems and pressure switch activation in injector sys tems Average Cycle 2 Time Average Cycle 3 Time Average Duty Cycle The average percentage of time the unit has been pumping while it has been powered on Max Duty Cycle The highest percentage of time for one lubrication cycle that the unit has been pumping while it has been powered on Total Low Level Faults Total number of low level fa...

Page 44: ... input voltage mea sured by the internal circuit board Peak Input Board Volt age DC The peak input voltage measured by the internal circuit board Average Motor Current The average motor current mea sured by the unit Peak Motor Current The peak motor current mea sured by the unit Average Internal Tem perature The average internal tempera ture seen by the unit Peak Internal Tempera ture The peak int...

Page 45: ...e system vents Vent time can be modified A4 Max Alarm Retry Sets number of automatic retries after a Cycle or Pres sure Alarm Default 0 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 A5 Max Active Alarm Changes alarm output behavior Default OFF Uses alarm output to determine if a ...

Page 46: ...y moves to the next number field 6 Repeat steps 4 and 5 for each PIN Code prompt field 7 Press the ENTER button to save the PIN Code and exit Advanced Setup Entering Advanced Setup Press the UP ARROW button for 10 sec onds If the G3 was previously set up to require a PIN Code the LED next to the LOCK ICON lights indi cating a PIN Code is required 1 The cursor is automatically positioned to enter t...

Page 47: ...ht flashes indicating it is ready for programming 3 Use the UP or DOWN ARROW button to scroll through numerals 0 to 9 until the desired number appears in the second MM number field 4 Press the ENTER button to lock in the selection The next number field to the right flashes and the LED lights under SS indicating it is ready to program the seconds fields 5 Repeat steps 1 4 to set the SS seconds fiel...

Page 48: ...r 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 6 Repeat steps 1 4 to set the MM seconds fields 7 After pressing the ENTER button ...

Page 49: ...ss 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 A6 Clearing the Functional and Technical User Summary DMS Models only The Pump Summary shows run details since the last time the summary was cleared 1 Press the UP or DOWN ARROW button to move through Advanced Options until Advanced Option A6 is displa...

Page 50: ...ery second default or steady on Fault and Warning LEDs Illuminate 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 27 ON OFF 1 2 3 HH MM SS MM SS HH MM 2 3 1 P C C P C P C P ...

Page 51: ...ice the ON Time LED is now illuminated on the display The example shown in FIG 29 shows an ON Time of 8 minutes and 42 seconds before the lubrication cycle ends When the ON Time count reaches zero the pump shuts off again and the system again runs OFF Time cycle and the OFF Time LED is now again illu minated FIG 28 This sequence repeats itself until the device is reprogrammed or an alarm occurs If...

Page 52: ...ve 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 FIG 30 The example shown in FIG 30 shows sensor C1 with 5 cycles remaining Pressure Control A single triggered count in a pressure based system P1 Typically a pressure switch on the end of a line of injectors The LED next to the appropriate sensor ...

Page 53: ...e Pump ON and enter the rest cycle Pump OFF Rest Mode Pump OFF Controls In Max models the Rest Mode Pump OFF is controlled by machine counts If the Machine Count is set to a value greater than 0000 and the Backup Time option is activated the display will alternate between Machine Counts and Backup Time If Machine Count has been set to a value greater than 0000 and the Backup Time option is NOT act...

Page 54: ...imum rest time has been set The LED next to 1 2 3 illuminates FIG 35 The display shows the amount of time remain ing till a fault The example shown in FIG 35 shows 4 hours and 17 minutes remaining until a fault occurs If the Machine Count requirements are met the unit will exit the Rest Mode Pump OFF and enter the Lubrication Mode Pump ON OFF Time In Max models if the Machine Count is set to 0000 ...

Page 55: ...1 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 Pres sure Backup Time See Max Model Lubrication Mode Controls page 52 Prelube Delay The Pr...

Page 56: ...Run Mode 56 332305B Manual Run Cycle To run an extra non programmed lubrica tion cycle push the Manual Start button NOTE Manual Run option is not available while unit is in Vent Mode ...

Page 57: ...d 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 addi tional lubricant needs to be added Unit continues to operate as normal for a limited period of time until a low level alarm is triggered...

Page 58: ...g System fails to relieve pressure or a lubrication cycle was not completed in the user defined amount of time Unit will continue to oper ate for the number of lubri cation cycles set by the warning retry parameter see Advanced Program ming page 45 If the warning condition clears itself on the next automatic lubrication cycle the warning is cleared and the unit continues normal operation Examine s...

Page 59: ... sensor alarm at the same time Examine system to deter mine if you have a plugged or broken line or other component failure i e divider valve injector Press and hold the RESET but ton to clear fault Machine Count Fault 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 t...

Page 60: ...ntinued use at excessive motor currents could reduce life or cause permanent dam age Examine system to make sure it is operating cor rectly A blocked line could create excessive motor current Examine pump to ensure that it is rotating properly If necessary contact Graco Customer Service ON OFF 1 2 3 HH MM SS MM SS HH MM 2 3 1 P C C P C P C P ON OFF 1 2 3 HH MM SS MM SS HH MM 2 3 1 P C C P C P C P ...

Page 61: ...e dam age 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 USB Error An error occurred during a DMS operation Read the Troubleshoot ing section of this manual page 62 for error num bers and fault descrip tions ON OFF 1 2 3 HH MM SS MM SS HH MM 2 3 1 P C C P C P C P ON OFF 1 2 3 HH MM SS...

Page 62: ...of the display 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 controller lights and functions Failed mot...

Page 63: ...program setting file not found Verify that the pump program setting folder structure and file are stored correctly on the flash drive See Stor ing Pump Program Settings to the Flash Drive page 37 for instructions USB Error 12 Pump program settings directory not found Verify that the pump program setting folder structure and file are stored correctly on the flash drive See Stor ing Pump Program Set...

Page 64: ... 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 Daily Display Keep display clean using a clean dry cloth Monthly External Wiring Harness Verify external harnesses are secure ...

Page 65: ...4 1 42 13 18 17 34 36 33 37 41 21 30 15 4 3 31 Follower Plate Models 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 Only Low Level Oil Models Only 66 67 1 12 ...

Page 66: ...40a 44 35 14 1 41 13 18 17 34 16 36 33 37 42 21 30 15 4 3 31 Follower Plate Models 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 61 62 40b 3 27 1 45 60 23 57 Low Level Grease Models Only 67 66 Low Level Oil Models Only 12 ...

Page 67: ...e models 96G105 96G120 96G164 96G165 1 16 cont PADDLE stirring 16 Liter models without follower plate models 96G106 96G121 96G166 96G168 96G169 96G185 1 PADDLE stirring 2 Liter models with follower plate models 96G018 96G020 96G024 96G026 96G115 96G132 included in Kit 571045 1 PADDLE stirring 4Liter models with follower plate models 96G090 96G094 96G113 96G116 96G128 96G133 1 17 PUMP element inclu...

Page 68: ... 96G181 96G183 96G186 96G188 Ref Part Description Qty 35 WIPER stirring models without fol lower plate models 96G017 96G019 96G021 96G023 96G025 96G030 96G032 96G035 96G037 96G088 96G089 96G092 96G093 96G096 96G100 96G103 96G106 96G110 96G112 96G118 96G121 96G125 96G127 96G141 96G146 96G151 96G159 96G160 96G162 96G164 96G165 96G168 96G169 96G177 96G178 96G181 96G183 96G185 96G188 included in Kit 5...

Page 69: ... 96G094 96G113 96G116 96G128 96G133 1 45 24D838 BAFFLE low level 2 liter models 96G017 96G019 96G021 96G023 96G025 96G030 96G032 96G035 96G037 96G098 96G110 96G125 96G178 1 Ref Part Description Qty 24E246 BAFFLE low level 4 liter models 96G088 96G092 96G096 96G099 96G103 96G111 96G118 96G126 96G141 96G143 96G145 96G151 96G153 96G155 96G157 96G159 96G160 96G161 96G162 96G181 96G183 1 24F836 BAFFLE ...

Page 70: ...16 liter models 96G106 96G121 96G166 96G168 96G169 96G185 3 62 ADAPTER reservoir models 96G088 96G090 96G092 96G094 96G096 96G097 96G099 96G100 96G103 96G106 96G108 96G109 96G111 96G113 96G116 96G118 96G121 96G123 96G124 96G126 96G128 96G133 96G141 96G146 96G151 96G162 96G164 96G166 96G168 96G169 96G175 96G177 96G181 96G183 96G185 96G186 1 66 126417 NUT oil models 96G107 96G108 96G109 96G122 96G12...

Page 71: ... MPa 172 36 bar 1 563161 VALVE pressure relief 3000 psi 20 68 MPa 206 84 bar 1 563190 VALVE pressure relief 5500 psi 37 92 MPa 379 21 bar 1 a ti15644 b a adjustment screw b locking nut Part Description Qty 571039 FUSE 12 volt DC 1 571040 FUSE 24 volt DC 1 Kit No Description Manual Number 571026 KIT output union 3 pump 3A0523 571063 KIT output union 2 pump 571028 KIT return to reservoir NPT include...

Page 72: ... DC Max Switching Capacity Resistive 50 VA 60 W Inductive 25 VA 30 W Min Permissible Load Resistive 10 µA 10m VDC Inductive 10 µA 10m VDC 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 ope...

Page 73: ...nt Ambient Temps 40 F 158 F 40 C to 70 C Weight Dry includes power cord and plug Without follower plate 13 3 lbs 6 03 kg With follower plate 14 2 lbs 6 44 kg Wetted Parts nylon 6 6 PA trogamid T5004 060 zinc plated steel carbon steel alloy steel stainless steel nitrile rubber buna N bronze nickel plated alnico chemically lubri cated acetal aluminum PTFE Grillamid Sound Data 60 dB Model Height Widt...

Page 74: ... 1 or Option 2 See P N 126916 template FIG 37 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 75: ...Notes 332305B 75 Notes ...

Page 76: ...f 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 ...

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Graco G3 Series, Instruction Manual

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Summary of Contents for G3 Series

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