Graco 332291B G3 Standard Automatic Lubrication Pump Users Manual 332291B, Pump, English
2015-04-02
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Instructions G3 Standard Automatic Lubrication Pump 332291B EN For dispensing of NLGI Grades #000 to #2 greases and oil with at least 40cSt. For Professional Use Only. Not approved for use in explosive atmospheres or hazardous locations. Part Nos., page 3 5100 psi (35.1 MPa, 351.6 bar) Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. TI14705 Conforms to ANSI/UL 73 Certified to CAN/CSA Std. 22.2 No 68-09 3132066 Contents Part / Model Numbers . . . . . . . . . . . . . . . . . . . . . . . 3 2 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 8 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 12 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 3 16 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Understanding the Model Number . . . . . . . . . . . 4 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 8 Choosing an Installation Location . . . . . . . . . . . . 9 System Configuration and Wiring . . . . . . . . . . . 10 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Connecting to Auxiliary Fittings . . . . . . . . . . . . . 18 Setting Pump Outlet Volume . . . . . . . . . . . . . . . 19 Loading Grease . . . . . . . . . . . . . . . . . . . . . . . . 19 Filling Oil Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 No Controller Operation . . . . . . . . . . . . . . . . . . . . 22 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Parts - 2 Liter Models . . . . . . . . . . . . . . . . . . . . . . 26 Parts - 4 Liter and Larger Models . . . . . . . . . . . . . 27 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Mounting Pattern . . . . . . . . . . . . . . . . . . . . . . . . 33 Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 34 Graco Information . . . . . . . . . . . . . . . . . . . . . . . 34 2 332291B Part / Model Numbers Part / Model Numbers The Part Number is a six-digit unique number that is only used to order the G3 Pump. Directly related to this six digit Part Number is the configured Graco Model Number. This configured 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 4. The tables below shows the relationship between each Part Number and its related Model Number. 2 Liter Models Part Numbers 96G000 96G001 96G002 96G003 96G005 96G006 96G007 96G008 96G050 96G059 96G182 8 Liter Models Model Number G3-G-12NC-2L0000-00C00000 G3-G-24NC-2L0000-00C00000 G3-G-ACNC-2L0000-0D000000 G3-G-12NC-2L0A00-L0C00000 G3-G-24NC-2L0A00-L0C00000 G3-G-24NC-2FA00-L0C00000 G3-G-ACNC-2L0A00-LD000000 G3-G-ACNC-2LFA00-LD00000 G3-A-24NC-2L0A00-L0C00000 G3-A-ACNC-2L0A00-LD000000 G3-G-24NC-2L0A00-0D00L000 4 Liter Models Part Numbers 96G038 96G040 96G042 96G044 96G048 96G051 96G053 96G055 96G060 96G062 96G179 96G184 332291B Model Number G3-G-12NC-4L0L00-00C00000 G3-G-24NC-4L0000-00C00000 G3-G-ACNC-4L0000-0D000000 G3-G-12NC-4L0A00-L0C00000 G3-G-24NC-4L0A00-L0C00000 G3-A-24NC-4L0A00-L0C00000 G3-G-24NC-4LFA00-L0C00000 G3-G-ACNC-4L0A00-LD000000 G3-A-ACNC-4L0A00-LD000000 G3-G-ACNC-4LFA00-LD000000 G3-G-ACNC-4LFA00-0D00L000 G3-G-24NC-4L0A00-0D00L000 Part Numbers 96G039 96G041 96G043 96G045 96G049 96G052 96G056 96G061 96G187 Model Number G3-G-12NC-8L0000-00C00000 G3-G-24NC-8L0000-00C00000 G3-G-ACNC-8L0000-0D000000 G3-G-12NC-8L0A00-L0C00000 G3-G-24NC-8L0A00-L0C00000 G3-A-24NC-8L0A00-L0C00000 G3-G-ACNC-8L0A00-LD000000 G3-A-ACNC-8L0A00-LD000000 G3-G-ACNC-8LFA00-0D00L000 12 Liter Models Part Numbers 96G057 96G171 Model Number G3-G-ACNC-120A00-LD000000 G3-G-24NC-120000-00C00000 16 Liter Models Part Numbers 96G058 96G172 Model Number G3-G-ACNC-160A00-LD000000 G3-G-24NC-160000-00C00000 3 Part / Model Numbers Understanding the Model Number Use the Code Sample provided below to identify each component’s location in the Model Number. The options for each component that make up the code are provided on the lists below. NOTE: Other pump configurations are available that are not documented in this manual. Contact Graco Customer Service or your local Graco distributor for assistance. G 3 - G - Code Sample: a a N C b b - G3 - G = Identifies pump as being a G3; G = Grease G3 - A = Identifies pump as being a G3; A = Oil Code aa: Power Source • • • 0 f 0 f d e - g h • 0 = No Follower Plate i 0 j 0 0 k m n 0 p Code e: Low Level Option A = External Low Level 0 = No Low Level monitoring Code ff: Options • NC = No Controller Code cc: Reservoir Capacity (Liters) • • • • • c • • 12 = 12 Volts DC 24 = 24 Volts DC AC = 100 - 240 Volts AC Code bb: Operation Control • c 2L = 2 Liters 4L = 4 Liters 8L = 8 Liters 12 = 12 Liters 16 = 16 Liters 00 = No Options Code g, h, i, j, k, m, n, p NOTE: Codes g - p relate to a specific location on the G3 pump. See FIG. 1 for these locations. • • • • C = CPC D = DIN L = Low Level 0 = Not populated Code d: Follower Plate Installed • F = Follower Plate Installed k m h g i j n p FIG. 1 4 332291B 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. 332291B 5 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 surgical treatment. • Do not point dispensing device at anyone or at any part of the body. • Do not put your hand over the fluid outlet. • Do not stop or deflect leaks with your hand, body, glove, or rag. • Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing equipment. • Tighten all fluid connections before operating the equipment. • Check hoses and couplings daily. Replace worn or damaged parts immediately. PRESSURIZED EQUIPMENT HAZARD Over-pressurization can result in equipment rupture and serious injury. • A pressure relief valve is required at each pump outlet. • Follow Pressure Relief Procedure in this manual before servicing. PLASTIC PARTS CLEANING SOLVENT HAZARD Many solvents can degrade plastic parts and cause them to fail, which could cause serious injury or property damage. • Use only compatible water-based solvents to clean plastic structural or pressure-containing parts. • See Technical Data in this and all other equipment instruction manuals. Read fluid and solvent manufacturer’s MSDSs and recommendations. MOVING PARTS HAZARD Moving parts can pinch, cut or amputate fingers and other body parts. • Keep clear of moving parts. • Do not operate equipment with protective guards or covers removed. • Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources. PERSONAL PROTECTIVE EQUIPMENT Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to: • Protective eyewear, and hearing protection. • Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer 6 332291B Installation Installation Grounding The equipment must be grounded. Grounding reduces the risk of electric shock by providing an escape wire for the electrical current in the event of malfunction or breakdown. This product is equipped with a cord having an equipment grounding conductor. The wire with insulation having an outer surface that is green with or without yellow stripes is the grounding wire. Component Identification M K A L Oil Models Grease Models C Grease Models with Follower Plate E D H F J 96GXXX G3-G-24NC-2L0A00-L0C00000 I B FIG. 2: Key: A B C D E F G Reservoir Adjustable Pump Element (1 included. Can accommodate 3 total) Pressure Relief Valve (Not included / required for each outlet - Available from Graco. See Parts, page 30.) Zerk Inlet Fill Fitting (1 included / grease models only) Pump Outlet Plug (2 included) Volume Control Spacers (2 included. More spacers = less output volume per stroke) (also see FIG. 13, page 19) Fuse (DC models only - Not included, not shown. Available from Graco. See Parts, page 30.) 332291B H I J K L M Power / Sensor Panel (both sides; only one side shown) Part Number / Model Number example only shown, (see page 4, Understanding the Model Number, for details) Power Cord (DIN shown) Follower Plate (grease models only / not available on all grease models) Vent Hole for Follower Plate (grease models only / not available on all grease models) Fill cap (oil models only) 7 Installation Typical Installation Divider Installations B D E A F Injector Installations E H B D A A Connected to fuse / power B Pressure relief valve (Not included/ required for each outlet user supplied. See Parts, page 30) D Series progressive divider valves (Divider Installations) - Injectors (Injector Installations) E To lube points 8 F G F - Proximity Switch (Divider Installations) - Pressure switch (Injector Installations) G Vent valve (Not included / available from Graco. See Parts, page 31.) H Return to reservoir 332291B Installation Choosing an Installation Location 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. 332291B Always mount the G3 oil models upright. • If the G3 grease model is going to be operated in a tilted or inverted position for any period of time, you must use a model that includes a follower plate, otherwise the G3 must be mounted upright. Refer to your model number to confirm if a follower plate was installed on your pump. See page 4, Understanding the Model Number to identify this character in your model number. • Use the three fasteners (included) to secure the G3 to the mounting surface. • Some installations may require an additional reservoir support bracket. Consult your Graco distributor for assistance with this installation. Refer to the two mounting hole layouts provided in the Mounting Pattern section of this manual, page 33. NOTE: The two mounting hole layouts provided in the Technical Data section show the only correct installation patterns to use for mounting the G3. No other installation configurations should be used. • • Use designated mounting holes and provided configurations only. 9 Installation System Configuration and Wiring Fuses NOTICE . 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. 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. If an attachment plug is required in the end use application: • it must be rated for the product electrical specifications. • it must be an approved, 3-wire grounding type attachment plug. • it must be plugged into an outlet that is properly installed and grounded in accordance with all local codes and ordinances. • 10 when repair or replacement of the power cord or plug is required, do not connect the grounding wire to either flat blade terminal. Input Voltage 12 VDC 24 VDC Fuse Value 7.5 A 4A Graco Kit No. 571039 571040 Recommendations for Using Pump in Harsh Environments • Use pump with CPC style power cable. • If using a DIN style power or alarm harness with a right angle mating connector, make sure the connector does not exit the unit in the UP direction. • Use a corrosion preventative electrical grease on all contacts. 332291B Installation Wiring and Installation Diagrams The following Table identifies the wiring and installation diagrams for the cable included with the pump provided in this manual. Diagram 332291B Symbol Page # Power DIN AC 12 Power DIN DC 13 Power CPC DC 14 Low Level Outputs 15 11 Installation Power DIN AC - 15 foot: Part No. 16U790 Pin and Related Wire Color (FIG. 3) Pin Pin Name 1 2 3 4 Line NEUTRAL Not Used GROUND Color Black White Not Used Green Connector on Housing Connector on Cable (4) (4) (2) (1) (1) (2) (3) Example Wiring Diagram 1 2 3 4 FIG. 3 12 332291B Installation Power DIN DC - 15 foot: Part No. 16U790 NOTICE Be sure when power is applied that stirring paddle rotates clockwise (when viewed from the top). If it is wired incorrectly paddle could rotate counter-clockwise which will damage the pump’s internal components. If this happens, stop the pump immediately and wire unit correctly. Pin and Related Wire Color (FIG. 5) Pin Pin Name Color 1 2 3 4 -VDC +VDC Not Used Not Used Black White Not Used Green FIG. 4 Connector on Housing Connector on Cable (4) (4) (2) (1) (1) (2) (3) Example Wiring Diagram Ignition Switch Fuse 1 2 3 4 12V-pump - 7.5A - Graco kit #571039 24V pump - 4A - Graco kit #571040 FIG. 5 332291B 13 Installation Power CPC DC - 15 foot: Part No. 126217 Pin and Related Wire Color (FIG. 6) Pin Pin Name Color 1 2 3 4 5 6 7 Not Used -VDC +VDC Not Used Not Used Not Used Not Used Not Used Black White Not Used Not Used Not Used Green Connector on Housing Connector on Cable (2) (2) (3) (1) (3) (1) (7) (6) (4) (5) (4) (7) (5) (6) Example Wiring Diagram Ignition Switch Fuse 12V-pump - 7.5A - Graco kit #571039 24V pump - 4A - Graco kit #571040 1 2 3 4 5 6 7 FIG. 6 14 332291B Installation Low Level Outputs See Low Level Output Option, page 22 for functional description. See Technical Data, page 32 for ratings. Pin Pin Name 1 2 3 4 Not Used Not Used LL N.O. LL COM Connector on Housing Connector on Housing (4) (4) (3) (1) (1) (2) (3) (2) Example Wiring Diagram 1 2 3 4 G3 FIG. 7 332291B 15 Installation Part No. 124333: Cable Pin Out (M12) Part No. 124300: Field Wireable Pin Out (M12) Wire Colors Item No. Color 1 2 3 4 Brown White Blue Black Wire Colors Item No. 1 2 3 4 Color Brown White Blue Black FIG. 9 FIG. 8 16 332291B Installation Part No. 124594: 4 Pin Eurofast Field Wireable Connector Part No. 124595: 5 Pin Eurofast Field Wireable Connector FIG. 10 332291B FIG. 11 17 Setup Setup Connecting to Auxiliary Fittings Pressure Relief Follow the Pressure Relief Procedure whenever you see this symbol. 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. This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment. Relieve pressure in system using two wrenches working in opposite directions on pump element and pump element fitting to slowly loosen fitting only until fitting is loose and no more lubricant or air is leaking from fitting. NOTE: When loosening pump element fitting, do NOT loosen pump element. Loosening pump element will change the output volume. • Always use two wrenches working in opposite directions when connecting anything to pump element or auxiliary fittings. See FIG. 12 for an example. • Torque pump element fittings to 50 in. lbs (5.6 N•m). • When connecting pump element into housing torque to 50 in. lbs (5.6 N•m). Pressure Relief Valves To prevent over-pressurization, which can result in equipment rupture and serious injury, a pressure relief valve appropriate for the lubrication system must be installed close to every pump outlet to alleviate unintended pressure rises in the system and protect the G3 pump from damage. FIG. 12 18 • Only use a pressure relief valve that is rated for no more than the working pressure of the G3 pump it is installed on. See Technical Data, page 27. • 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 30. 332291B Setup Setting Pump Outlet Volume 3. Tighten pump element fitting. Torque fitting to 50 in. lbs (5.6 N•m). NOTE: • Before making any adjustments to pump volume, Relieve Pressure following procedure on page 18. • Only use Graco supplied spacers to control output volume. • It may be necessary to repeat this outlet volume setup procedure after the pump is operating to re-adjust the volume of dispensed fluids. 1. Use a wrench to turn pump element counter-clockwise to loosen. Do not remove entire pump element. Only back pump element out enough to allow spacer to be slid on or off. FIG. 13 Loading Grease To ensure optimal performance from the G3: • Only use NLGI #000 - #2 greases appropriate for your application, automatic dispensing, and the equipment’s operating temperature. Consult with machine and lube manufacturer for details. • The reservoir can be filled using a hand operated pump, pneumatic pump or electric transfer pump. • Do not overfill (FIG. 15). • Do not operate G3 without reservoir attached. 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 (FIG. 13). Do not use more than 2 spacers to adjust output volume. No. Spacers 2 1 0 Output Volume / Minute cubic inches cubic cm 0.12 2 0.18 3 0.25 4 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. 332291B NOTICE • Always clean fitting (D) with a clean dry cloth prior to filling reservoir. Dirt and/or debris can damage pump and/or lubrication system. • Care must be used when filling the reservoir using a pneumatic or electric transfer pump to not pressurize and break the reservoir. 19 Setup Models without a follower plate: For models using an external controller, start pump operation per your controller specifications. 1. Connect fill hose to inlet fitting (FIG. 14). E 3. Fill reservoir with grease until seal of follower plate breaches the vent hole (FIG. 16) and the majority of air is expelled from the reservoir. D vent hole FIG. 14 2. For higher viscosity fluids, start pump to rotate stirring paddle during fill to prevent air pockets from forming in grease. For models using an external controller, start pump operation per your controller specifications. FIG. 16 NOTE: Vent port, located in rear of reservoir, should not be used as an overfill port/indicator. 3. Fill reservoir with NLGI grease to max fill line. 4. Remove fill hose. NOTE: Vent port, located in rear of reservoir, should not be used as an overfill port/indicator. Changing Greases When changing greases, always use compatible fluids or greases. max fill line FIG. 15 4. Remove fill hose. Models with a follower plate: 1. Connect fill hose to inlet fitting (FIG. 14). 2. For higher viscosity fluids, start pump to rotate stirring paddle during fill to prevent air pockets from forming in grease. 20 332291B Setup Filling Oil Unit • Only use oil appropriate for your application, automatic dispensing, and the equipment’s operating temperature. Consult with machine and lube manufacturer for details. • The reservoir can be filled using a hand operated pump, pneumatic pump or electric transfer pump. • Do not overfill (FIG. 17). • Do not operate G3 without reservoir attached. • Only use oils with viscosity at least 40 cSt. FIG. 18 2. Only run pump until air is no longer dispensed with the lubricant coming out of element fitting (FIG. 19). a b FIG. 17 1. Remove fill cap (a). 2. Pour oil into reservoir to fill line (b). 3. Replace fill cap. Hand tighten cap, securely. FIG. 19 Priming 3. Tighten pump element fitting using two wrenches working in opposite directions (FIG. 18). NOTE: It is not necessary to prime pump every time pump is filled with lubricant. Pump only requires priming the first time it is used or if it is allowed to run dry. 1. Loosen pump element fitting (FIG. 18). NOTE: When loosening pump element fitting, do NOT loosen pump element. Loosening pump element will change the output volume 332291B 21 No Controller Operation No Controller Operation The G3 Pump can be controlled using an external, user supplied, power source and controller. Refer to the Typical Installation diagrams provided on page 8 for correct location of the required pump ground wire and fuses. NOTE: • • When using an external power source and controller, Pump ON (Run) Time should be set for no longer than 30 minutes. In most cases, Pump OFF (Rest) Time should be twice as long as Pump ON (Run) time. If alternative ON / OFF times are required, contact Graco Customer Service for assistance. Low Level Output Option Some G3 pumps without controllers include a Low Level Output Option. It can be configured with an M12 connector in code location “G” or with a DIN connector in code location “K”. (See Understanding the Model Number, 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 controller detects PINS 3 and 4 have momentarily closed. Grease Pumps When the grease level has reached a low warning level, PINS 3 and 4 momentarily close (1 time per paddle revolution) sending the signal that the fluid has reached a low level to the controller. To ensure that a low level condition has been met, 3 or more low level triggers must be detected within 1 minute or less. See FIG. 20 for an illustration of a typical Low Level Output response to low grease level. Typical Low Level Output Response with Low Level Fluid in Grease Models 200 ms Closed Contact Position Open 3s FIG. 20 22 332291B No Controller Operation Oil Pumps When the oil level has reached a low warning level, PINS 3 and 4 close, sending the signal to the controller that 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 seconds. See FIG. 21 for an illustration of a typical Low Level Output response to low oil level. Typical Low Level Output Response with Low Level Fluid in Oil Models Closed Contact Position Open FIG. 21 332291B 23 Troubleshooting Troubleshooting Problem Unit does not power on Unit does not power on (DC models only) Cause Incorrect/loose wiring Solution Refer to Installation instructions, page 7. 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. Reservoir retaining tabs are cracked or broken Replace reservoir. Lubricant leaks past seal located on the bottom of the reservoir Reservoir is being pressurized during filling Ensure vent hole is not plugged. Unit not pumping during ON cycle, but external controller functions Failed motor Replace unit. Air is trapped in the reservoir between the follower plate and lubricant 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 accommodate 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 configured Adjust external vent valve control time. Follower plate is not going down 24 If problem persists, contact Graco Customer Service or your local Graco distributor for assistance. 332291B Maintenance Maintenance Frequency Component Required Maintenance Keep all fittings clean using a clean dry cloth. Dirt and/or debris can damage pump and/or lubrication system. Daily and at refill Zerk Fittings 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. 332291B 25 Parts - 2 Liter Models Parts - 2 Liter Models 40b Follower Plate Models Only Low Level Grease Models Only 40a 43 45 44 35 42 57 27 1 41 16 36 60 23 13 15 Low Level Oil Models Only 12 14 67 18 3 37 21 66 1 33 1 Torque to 4 in. lbs (0.45 N.m) 3 42 26 17 3 2 Torque to 30 in. lbs (3.4 N.m) 3 Torque to 50 in. lbs (5.6 N.m) 332291B Parts - 4 Liter and Larger Models Parts - 4 Liter and Larger Models Follower Plate Models Only 40a 40b 43 44 Low Level Grease Models Only 41 42 45 36 35 57 27 1 61 16 62 13 14 60 15 12 18 23 Low Level Oil Models Only 3 37 21 33 1 67 17 3 66 1 Torque to 4 in. lbs (0.45 N.m) 3 4 2 2 Torque to 30 in. lbs (3.4 N.m) 3 Torque to 50 in. lbs (5.6 N.m) 332291B 27 Parts Parts Ref Part 1 Description Qty BASE, three pump housing 1 3 278142 COVER, bottom, with seal 1 4 115477 SCREW, mach, torx pan hd 9 12 127079 13 124396 RECT-RING, included in kit 571042, 571069, 571179 O-RING, 258, included in Kit 571042, 571044, 571045, 571069, 571179 1 15 BEARING, ball 1 17 18 16F368 21 278145 28 PLUG, pump, 3/4-16 27 123025 33 16A579 LABEL, safety 1 1 1 36 1 1 LABEL, brand 123741 40a 24E984 1 40b 16G021 1 40a 24B702 1 2 1 WIPER, stirring, models without follower plate - models 96G000, 96G001, 96G002, 96G003, 96G005, 96G007, 96G038-96G045, 96G048, 96G049, 96G055-96G058, 96G171, 96G172, 96G182, 96G184, included in Kit 571044 WIPER, stirring, models with follower plate - models 96G006, 96G008, 96G053, 96G062, 96G179, 96G187, included in Kit 571045 35 37 Qty PADDLE, low level, models 96G003-96G008, 96G038, 96G044, 96G045, 96G048, 96G049, 96G053, 96G055-96G058, 96G062, 96G179, 96G182, 96G184, 96G187 SCREW, M6, models 96G003-96G008, 96G038, 96G044, 96G045, 96G048, 96G049, 96G053, 96G055-96G058, 96G062, 96G179, 96G182, 96G184, 96G187 278136 1 1 Description 23 2 PLATE, ricer 16 Part 1 14 PADDLE, stirring, 2 Liter models without follower plate - models 96G000, 96G001, 96G002, 96G003, 96G005, 96G007, 96G182, included in Kit 571044, PADDLE, stirring, 4 Liter models without follower plate - models 96G038, 96G040, 96G042, 96G044, 96G048, 96G055, 96G184 PADDLE, stirring, 8 Liter models without follower plate - models 96G039, 96G041, 96G043, 96G045, 96G049, 96G056 PADDLE, stirring, 12 Liter models without follower plate - model 96G057, 96G171 PADDLE, stirring, 16 Liter models without follower plate - model 96G058, 96G172 PADDLE, stirring, 2 Liter models with follower plate - models 96G006, 96G008, included in Kit 571045 PADDLE, stirring, 4 liter models with follower plate - models 96G053, 96G062, 96G179 PUMP, element, included in Kit 571041 SPACER, stroke adjust, included in Kit 571041 Ref 40b 16G020 1 1 1 FITTING, zerk, grease, not included on models 96G050-96G052, 96G059-96G061 RESERVOIR, 2 liter, grease, 96G000-96G008, 96G182, included in Kit 571042, 571069 RESERVOIR, 2 liter, oil, 96G050, 96G059, included in Kit 571179 RESERVOIR, 4 liter, grease, 96G038, 96G040, 96G042, 96G044, 96G048, 96G053, 96G055, 96G062, 96G179, 96G184, included in Kit 571183 RESERVOIR, 4 liter, oil, 96G051, 96G060 1 1 1 1 1 2 332291B Parts Ref 40a 40b 40a 40a 41 42 43 44 45† † † † † 57 Part Description RESERVOIR, 8 liter, grease, 96G039, 96G041, 96G043, 96G045, 96G049, 96G056, 96G187 RESERVOIR, 8 liter, oil, 96G052, 96G061, included in Kit 571182 RESERVOIR, 12 liter, 96G057, 96G077, 96G171 RESERVOIR, 16 liter, 96G058, 96G172 SEAL, follower plate, 2 liter models 278139 96G006, 96G008 SEAL, follower plate, 4 liter models 16F472 96G053, 96G062, 96G179 PLATE, follower, 2 liter models 96G006, 96G008 PLATE, follower, 4 liter models 96G053, 96G062, 96G179 ROD, follower plate, 2 liter models 96G006, 96G008 ROD, follower, 4 liter models 96G053, 96G062, 96G179 SPRING, compression, 2 liter models 96G006, 96G008 SPRING, compression, 4 liter models 96G053, 96G062, 96G179 BAFFLE, low level, 2 liter models 24D838 96G003, 96G005, 96G007, 96G182 BAFFLE, low level, 4 liter models 24E246 96G044, 96G048, 96G055, 96G184 BAFFLE, low level, 8 liter models 24F836 96G045, 96G049, 96G052, 96G056, 96G061 BAFFLE, low level, 12 liter models 24F923 96G057 BAFFLE, low level, 16 liter models 24F924 96G058 BEARING, sleeve, models 96G003-96G008, 96G038, 96G044-96G045, 96G048, 117156 96G049, 96G053, 96G055-96G058, 96G062, 96G179, 96G182, 96G184, 96G187 332291B Qty Ref 1 58 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 Part Description LABEL, models 96G002, 96G007, 96G008, 96G042, 96G043, 196548 96G055-96G062, 96G179, 96G187 WASHER, low level, models 96G003-96G008, 96G033-96G038, 96G044-96G045, 96G048, 60 16D984 96G049, 96G053, 96G055-96G058, 96G062, 96G179, 96G182, 96G184, 96G187 RESERVOIR, mid-section, 8 liter models 96G039, 96G041, 96G043, 96G045, 96G049, 96G052, 96G056, 96G061, 96G187 61 RESERVOIR, mid-section, 12 liter models 96G057, 96G171 RESERVOIR, mid-section, 16 liter models 96G058, 96G172 ADAPTER, reservoir, models 96G038-96G045, 96G048, 96G049, 96G051-96G053, 96G055, 96G057, 96G058, 62 96G060-96G062, 96G171, 96G172, 96G179, 96G184, 96G187 NUT, oil, models 96G050, 66 126417 96G051, 96G052, 96G059, 96G060, 96G061 FLOAT, oil, models 96G050, 67 24N806 96G051, 96G052, 96G059, 96G060, 96G061 CABLE,15 ft (4.5 m), SOOW 126217 w/7pos, 3 pin, 90 deg (See Wiring Diagram, page 14) 200 CABLE, DIN, bare, (See Wiring 16U790 Diagram, page 12) Qty 1 2 1 2 3 1 1 1 1 29 Parts Ref Part 124300 201 124333 124301 202 124594 124595 Description Qty CABLE, M12, 15 ft., 4 wire, straight male to flying leads (See Wiring Diagram, page 16) CABLE, M12, 15 ft., 4 wire, straight male to female (See Wiring Diagram, page 16) CONNECTOR, Eurofast, fem, straight, 4 Pin CONNECTOR, Eurofast, 4 Pin (see wiring diagram, page 17) CONNECTOR, Eurofast, 5 Pin (see wiring diagram, page 17) 1 1 1 1 1 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. 57, Part No. 117156 when ordering this part. Part Description Qty VALVE, pressure relief, 500-3500 psi (3.44 MPa, 34.4 bar - 24.1 MPa, 241 16C807 bar), Set pressure 3000 psi + 10% (20.68 MPa, 206.8 bar + 10%) Included in Kit 571028 VALVE, pressure relief, 750 psi (5.17 563156 MPa, 51.71 bar) VALVE, pressure relief, 1000 psi 563157 (6.89 MPa, 68.95 bar) VALVE, pressure relief, 1500 psi 563158 (10.34 MPa, 103.42 bar) VALVE, pressure relief, 2000 psi 563159 (13.78 MPa, 137.89 bar) VALVE, pressure relief, 2500 psi 563160 (17.23 MPa, 172.36 bar) VALVE, pressure relief, 3000 psi 563161 (20.68 MPa, 206.84 bar) 1 1 1 1 1 1 1 Fuses Pressure Relief Valves Important Information regarding Pressure Relief Valve 16C807. Part 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. NOTE: Turning adjustment screw (a) clockwise increases pressure. a Description Qty 571039 FUSE, 12 volt DC 1 571040 FUSE, 24 volt DC 1 b ti15644 a = adjustment screw b = locking nut The pressure adjustment screw will require periodic adjustments. Whenever the valve is set/adjusted (after the set point is found) it is important to ensure that the valve is not bottomed out and there is at least 1/2 turn of adjustment remaining. This is determined by turning the screw (a) 1/2 turn and then back turning it out again. 30 332291B Parts Installation and Repair Kits Kit No. 571026 571063 571028 571071 24M478 24M479 24M480 24N182 571036 571041 571042 571069 571044 571045 571046 571047 571058 571070 571060 571179 571182 571183 332291B Description KIT, output union, 3 pump KIT, output union, 2 pump KIT, return to reservoir NPT, includes pressure relief valve 16C807 KIT, return to reservoir BSPP, includes pressure relief valve 16C807 KIT, vent valve, 12 volt DC, NO, NPT DEU KIT, vent valve, 24 volt DC, NO, NPT DEU KIT, vent valve, 115 VAC, NO, NPT, DIN KIT, vent valve, 230 VAC KIT, cover with “G” label KIT, pump element, includes Ref 17, 18, 33 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, output adapter, NPT KIT, output, adapter, BSPP KIT, fill, zerk, leakproof 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 Manual Number 3A0523 3A0525 3A0526 NA 3A0533 3A0534 3A0535 3A0522 NA 3A0534 31 Technical Data Technical Data Maximum Working Pressure 5100 psi (35.1 MPa, 351.6 bar) Power 100-240 VAC 88 - 264 VAC; 0.8 A current, 90 VA Power, 47/63 Hz, Single phase, inrush/locked rotor, max 40A (1ms) 12 VDC 9 - 16 VDC; 5 A current, 60 W, inrush/locked rotor 12 A 24 VDC 18 - 32 VDC; 2.5 A current, 60 W, inrush/locked rotor 6 A Outputs - Low Level (Dry Contact) Contact Rating 10 Watts Maximum Switch Rating 200 VDC Maximum Switching Current 0.5 A Maximum Carry Current 1.2 A Maximum Fluid Grease Models Grease NLGI 000 - #2 Oil Models At least 40 cSt oil. Pumps Up to 3 Pump Output 0.12 in.3 (2 cm3) / minute 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), trogamid T5004-060, zinc plated steel, carbon steel, alloy steel, stainless steel, nitrile rubber (buna-N), bronze, nickel plated alnico, chemically lubricated acetal, aluminum, PTFE, Grillamid Sound Data <60 dB Dimensions Model 2L 4L 8L 12L 16L 32 Height Inches 13.25 14.50 18.50 23.00 27.50 Depth Width cm 33.65 36.83 47.00 58.42 69.85 Inches 8.00 9.25 9.25 9.25 9.25 cm 20.32 23.50 23.50 23.50 23.50 Inches cm 9.00 10.00 10.00 10.00 10.00 22.86 25.40 25.40 25.40 25.40 332291B Technical Data Mounting Pattern (For correct mounting configuration, choose either Option 1 or Option 2). See P/N 126916 template. Option 1 0.367inch 9.3 mm 7.087 inch 180.0 mm 2x Ø 0.366 inch 9.3 mm 1.180 inch 30.0 mm 3.268 inch 83.0 mm 3.544 inch 90.0 mm Option 2 0.722 inch 18.3 mm 6.378 inch 162.0 mm 2x Ø 0.366 inch 9.3 mm 0.708 inch 18.0 mm 3.740 inch 95.0 mm 3.189 inch 81.0 mm FIG. 22 332291B 33 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations. This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco. This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation. THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale. GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties. In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise. FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées. Graco Information For the latest information about Graco products, visit www.graco.com. TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 612-623-6928 or Toll Free: 1-800-533-9655, Fax: 612-378-3590 All written and visual data contained in this document reflects the latest product information available at the time of publication. Graco reserves the right to make changes at any time without notice. For patent information, see www.graco.com/patents. Original instructions. This manual contains English. MM 332291 Graco Headquarters: Minneapolis International Offices: Belgium, China, Japan, Korea 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. www.graco.com revised April 2014
Source Exif Data:
File Type : PDF File Type Extension : pdf MIME Type : application/pdf PDF Version : 1.4 Linearized : Yes Page Mode : UseOutlines XMP Toolkit : 3.1-701 Format : application/pdf Title : 332291B, G3 Standard Automatic Lubrication Pump, English Creator : Terri Howard Description : For dispensing NLGI Grades #000 to #2 greases and oil wit at least 40cSt. Subject : 332291, G3 Standard, Lubrication Pump, Standard Automatic Lubrication Pump, G3, 332291B, 332291EN, 332291EN-B, MM 332291 Create Date : 2009:12:15 10:08:57Z Modify Date : 2014:05:09 13:07:31-05:00 Creator Tool : FrameMaker 11.0 Metadata Date : 2014:05:09 13:07:31-05:00 Web Statement : 332291A G3 Standard Automatic Lbrication Pump Job Ref : Z087900 Keywords : 332291, G3 Standard, Lubrication Pump, Standard Automatic Lubrication Pump, G3, 332291B, 332291EN, 332291EN-B, MM 332291 Producer : Acrobat Distiller 10.1.9 (Windows) Copyright : December 2013, revised April 2014 Marked : True Document ID : uuid:c5264760-a9e9-4f78-b8f2-14a4ff1f50a5 Instance ID : uuid:931146ca-8feb-4063-9c17-6aab25a11177 Page Count : 34 Language : en Author : Terri HowardEXIF Metadata provided by EXIF.tools