Graco 332305B G3 Max Automatic Lubrication Pump Users Manual 332305B, Pump, English

332305B to the manual ba70c199-fdf8-471d-ba51-b2e401ca8343

2015-04-02

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Instructions

G3 Max Automatic
Lubrication Pump

332305B
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
12 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 4
16 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Understanding the Model Number . . . . . . . . . . . 5
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 9
Choosing an Installation Location . . . . . . . . . . . 10
System Configuration and Wiring . . . . . . . . . . . 11
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Connecting to Auxiliary Fittings . . . . . . . . . . . . . 23
Setting Pump Outlet Volume . . . . . . . . . . . . . . . 24
Loading 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 . . . . . . . . . . . . . . . . . . . . .
Operation / Data Log . . . . . . . . . . . . . . . . . . . . . . .
System Event Log . . . . . . . . . . . . . . . . . . . . . . .
Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Summary . . . . . . . . . . . . . . . . . . . . .
Technical Summary . . . . . . . . . . . . . . . . . . . . .
Advanced Programming . . . . . . . . . . . . . . . . . . . .
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault / Warning Scenarios . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts - 2 Liter Models . . . . . . . . . . . . . . . . . . . . . .
Parts - 4 Liter and Larger Models . . . . . . . . . . . . .
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Pattern . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty . . . . . . . . . . . . . . . . . . .
Graco Information . . . . . . . . . . . . . . . . . . . . . . .

37
39
39
40
42
44
45
51
51
57
57
62
64
65
66
67
72
73
74
76
76

332305B

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 5. The tables below shows the relationship between each Part Number and its related Model
Number.

2 Liter Models
Part
Numbers

Model Numbers

4 Liter Models
Part
Numbers

Model Numbers

96G017
96G018
96G019
96G020
96G021
96G023
96G024
96G025
96G026
96G030
96G031
96G032

G3-G-24MX-2L0L00-10CV00R0
G3-G-24MX-2LFL00-10CV00R0
G3-G-ACMX-2L0L00-1D0V0000
G3-G-ACMX-2LFL00-1D0V0000
G3-G-12MX-2L0L00-1DMVA2R3
G3-G-24MX-2L0L00-1DMVA2R3
G3-G-24MX-2LFL00-1DMVA2R3
G3-G-ACMX-2L0L00-1DMVA2R3
G3-G-ACMX-2LFL00-1DMVA2R3
G3-G-12MX-2L0L00-10C00000
G3-G-24MX-2L0L00-10C000R0
G3-G-ACMX-2L0L00-1D000000

96G088

G3-G-24MX-4L0L00-10CV00R0

96G090

G3-G-24MX-4LFL00-10CV00R0

96G092

G3-G-ACMX-4L0L00-1D0V0000

96G094

G3-G-ACMX-4LFL00-1D0V0000

96G096
96G099

G3-G-12MX-4L0L00-1DMVA2R3
G3-G-12MX-4L0L00-UDMVA1R2

96G103
96G108
96G111

G3-G-24MX-4L0L00-1DMVA2R3
G3-A-24MX-4L0L00-1DMVA2R3
G3-G-24MX-4L0L00-UDMVA1R2

96G113

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

96G116

G3-G-24MX-4LFL00-UDMVA1R2

96G035

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

96G118

G3-G-ACMX-4L0L00-1DMVA2R3

96G036

G3-G-24MX-2L0L05-10CV0000

96G123

G3-A-ACMX-4L0L00-1DMVA2R3

96G037
96G098
96G107
96G110
96G115

G3-G-ACMX-2L0L00-1D00A000
G3-G-12MX-2L0L00-UDMVA1R2
G3-A-24MX-2L0L00-1DMVA2R3
G3-G-24MX-2L0L00-UDMVA1R2
G3-G-24MX-2LFL00-UDMVA1R2
G3-A-ACMX-2L0L00-1DMVA2R3

96G126

G3-G-ACMX-4L0L00-UDMVA1R2

96G128

G3-G-ACMX-4LFL00-1DMVA2R3

96G133

G3-G-ACMX-4LFL00-UDMVA1R2

96G141

G3-G-12MX-4L0L00-10C00000

96G143

G3-G-24MX-4L0L00-10C00000

96G145

G3-G-ACMX-4L0L00-1D000000

96G151

G3-G-12MX-4L0L05-10CV0000

96G153

G3-G-12MX-4L0L05-U0CV0100

96G155

G3-G-24MX-4L0L05-10CV0000

96G157

G3-G-24MX-4L0L05-U0CV0100

96G159

G3-G-12MX-4L0L05-00C0010M

96G160

G3-G-24MX-4L0L05-00C0010M

96G161

G3-G-12MX-4L0L05-U0C0010M

96G162

G3-G-24MX-4L0L05-U0C0010M

96G175

G3-A-ACMX-4L0L00-UDMVA1R2

96G181

G3-G-24MX-4L0L03-00C00100

96G183

G3-G-ACMX-4L0L00-1D00A000

96G188

G3-A-24MX-4L0L05-U0C0010M

96G122
96G125
96G132

G3-G-ACMX-2L0L00-UDMVA1R2
G3-G-ACMX-2LFL00-UDMVA1R2

96G174
96G178

G3-A-ACMX-2L0L00-UDMVA1R2
G3-G-24MX-2L0L00-0D00A100

332305B

Part / Model Numbers

8 Liter Models
Part
Numbers

Model Numbers

96G089

G3-G-24MX-8L0L00-10CV00R0

96G093

G3-G-ACMX-8L0L00-1D0V0000

96G097

G3-G-12MX-8L0L00-1DMVA2R3

96G100

G3-G-12MX-8L0L00-UDMVA1R2

96G104

G3-G-24MX-8L0L00-1DMVA2R3

96G109
96G112

G3-A-24MX-8L0L00-1DMVA2R3

96G119

G3-G-ACMX-8L0L00-1DMVA2R3

96G124

G3-A-ACMX-8L0L00-1DMVA2R3

96G127

G3-G-ACMX-8L0L00-UDMVA1R2

96G142

G3-G-12MX-8L0L00-10C00000

96G144

G3-G-24MX-8L0L00-10C00000

96G146

G3-G-ACMX-8L0L00-1D000000

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

G3-G-24MX-8L0L00-UDMVA1R2

12 Liter Models
Part
Numbers
96G105
96G120
96G164
96G165

Model Numbers
G3-G-24MX-120L00-1DMVA2R3
G3-G-ACMX-120L00-1DMVA2R3
G3-G-24MX-120L05-10CV00000
G3-G-24MX-120L05-U0CV0100

16 Liter Models
Part
Numbers

Model Numbers

96G106

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

96G121

G3-G-ACMX-160L00-1DMVA2R3

96G166

G3-G-ACMX-160L00-1D0V0000

96G168

G3-G-24MX-160L05-10CV0000

96G169

G3-G-24MX-160L05-U0CV0100

96G185

G3-G-24MX-160L05-U0C0010M

332305B

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: Some pump configurations are not available. Contact Graco Customer Service or your local Graco distributor
for assistance.
G

Code Sample:

M X
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
•
•
•

k m n

Code e: Low Level Option
•
•

L = Low Level with Controller
0 = No Low Level monitoring
00 = No Options
03 = Powered Alarm Contact
05 = 5 Pin CPC power cable

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.

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
•
•

•
•
•

Code bb: Operation Control

•
•
•
•
•

Code ff: Options

12 = 12 Volts DC
24 = 24 Volts DC
AC = 100 - 240 Volts AC

•

F = Follower Plate Installed
0 = No Follower Plate

DMSTM Models

C = CPC
D = DIN
1, 2, 3 = Sensor Number
R = Remote Manual Run
M = Machine Count
A = Alarm Output
V = Vent Valve
0 = Not populated
U = USB Port

k
m

h
g
i

FIG. 1

332305B

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 symbol refers to procedure-specific risk. When
these symbols appear in the body of this manual, refer back to these warnings. Additional, product-specific warnings
may be found 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.

332305B

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

332305B

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
N

L
A
M
Oil Models
DMSTM Models

Grease Models
C

Grease Models with Follower
Plate

E
D
I

F
K

96GXXX
G3-G-24NC-2L0A00-L0C00000

J
B

FIG. 2:
Key:
A
B
C
D
E
F
G
H

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 71.)
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. 15, page 24)
Fuse (DC models only - Not included, not shown. Available
from Graco. See Parts, page 71.)
Control Panel

I
J
K
L
M
N
P

Power / Sensor Panel (both sides; only one side shown)
Part Number / Model Number example only shown, (see
pages 5, 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)
USB Port (DMS™ Models only)

332305B

Installation

Typical Installation
Divider Installations

D
E

Injector Installations

E
H

F
B

D
G

A
B
C
D
E
F

Connected to fuse / power
Pressure relief valve (Not included/required for each
outlet - user supplied. See Parts, page 71)
- Cycle indicator sensor cable (Divider Installations)
- Pressure switch cable (Injector Installations)
- Series progressive divider valves (Divider Installations)
- Injectors (Injector Installations)
To lube points
- Proximity Switch (Divider Installations)
- Pressure switch (Injector Installations)

332305B

G
H

Vent valve (Not included / available from Graco. See
Parts, beginning on page 67.)
Return to reservoir

Installation

Choosing an Installation Location

AUTOMATIC SYSTEM ACTIVATION HAZARD
Unexpected activation of the system could result in serious injury, including skin injection and amputation.
This device has an automatic timer that activates the pump lubrication system when power is connected or when
exiting the programming function. 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.

Always mount the G3 oil models upright.

•

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

•

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

•

Some installations may require an additional
reservoir support bracket. 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 74.
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.

332305B

Installation

System Configuration and Wiring
Fuses
.

Improper installation of the grounding conductor may
result in a risk of electric shock. This product must be
installed by a qualified electrician in compliance with
all state and local codes and regulations.

If the product is permanently connected:
•

it must be installed by a qualified electrician or serviceman.

•

it must be connected to a grounded, permanent wiring system.

If an attachment plug is required in the end use
application:
•

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

Never operate G3 Pump DC models without a
fuse installed.

•

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

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

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.

•

when repair or replacement of the power cord or
plug is required, do not connect the grounding wire
to either flat blade terminal.

332305B

Input Voltage

Fuse Value

Graco Kit No.

12 VDC

7.5 A

571039

24 VDC

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.

Installation

Alarm Output and Remote Illumination Response
The following tables include graphical representations of the connector as it appears on the unit, a pin-out associated
with the connector and a typical installation wiring diagram. An internal representative wiring diagram is included
where it is deemed useful.
Wire colors provided on these pages only refer to the power cable provided by Graco with this product.
Standard Remote
Illumination
(via 5 wire CPC power
cable)

Alarm Output
Unit in OFF Mode
Unit in ON Mode

Deactivated (off)
Deactivated (off)

Off
On
Toggles On and Off once
Activated (on)
per second
Toggles On and Off Toggles On and Off once
once per second
per second

Warning Condition
Fault Condition

Fault Condition
Toggles On and Off
(Advanced Programming
once per second
Setting A7 OFF)
Fault Condition
(Advanced Programming Activated (on)
Setting A7 ON)

Tri-Color Remote
Illumination
(via illuminated manual run
input)
Off
Green
Yellow
Red

Toggles On and Off once
per second

Red

Toggles On and Off once
per second

Red

Alarm Relay Response
Output Tied to Common
No Faults or
Warnings

N.O.
N.C.
N.O.

Warning

N.C.
Fault
(Advanced
Programming A7
OFF)
Fault
(Advanced
Programming
Setting A7 ON)

N.O.
N.C.
1 second

N.O.
N.C.

332305B

Installation

Wiring and Installation Diagrams
The following Table identifies the wiring and installation diagrams provided in this manual.
Diagram

Page #

Power DIN AC

Power DIN DC

Power CPC DC

Inputs (M12)

Vent Valve Outputs

Alarm Outputs

Illuminated Manual Run Input

332305B

Symbol

Kits: 571030, 571031,
571032, 571033

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)

(2)

(3)

Example Wiring Diagram

1
2
3
4

FIG. 3

332305B

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. 4)
Pin

Pin Name

Color

1
2
3
4

-VDC
+VDC
Not Used
Not Used

Black
White
Not Used
Green

Connector on Housing

Connector on Cable
(4)

(4)

(2)

(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. 4

332305B

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. 5

332305B

Installation

Power CPC DC - 5 Wire
Pin and Related Wire Color (FIG. 6)

Part No.: 126218: 15 ft (4.5 m)
Part No.: 126219: 20 ft (6.1 m)
Part No.: 126220: 30 ft (9.1 m)
NOTE: An Illuminated Remote Run Button Kit: 571030,
571031 for starting a manual run cycle if used in conjunction with a 5-wire CPC cable, is available from
Graco. Contact your local Graco distributor or Graco
Customer Service for additional information about these
kits.

Pin Name

Color

1
2
3
4
5
6
7

Not Used
-VDC
+VDC
LIGHT
MANUAL
Not Used
Not Used

Not Used
Black
Red
White
ORANGE
Not Used
Green

Connector on Cable

Connector on Housing

(2)

(3)

(1)
(3)

(4)

(7)

(1)

(6)

(4)

(7)

(5)

(6)

Example Wiring Diagram
Fuse

12V-pump - 7.5A - Graco kit #571039
24V pump - 4A - Graco kit #571040

L
1
2
3
4
5
6
7

FIG. 6

332305B

Installation

Inputs (M12)
See Technical Data, page 72 for ratings.

Connector on Housing

Pin-out

(1)
(4)

1 SW +
2 Not Used
3 SW -

(2)

4 Signal

(3)

Example Wiring Diagram
Dry Contacts
1
2
3
4
Sink (NPN) 2 or 3 wire

1
2
3
4

Source (PNP) 2 or 3 wire

1
2
3
4

FIG. 7

332305B

Installation

Vent Valve Outputs
See Technical Data, page 72 for ratings.

Connector on Housing

Pin-out

(3)

1 Not Used
2 Relief+
3 Relief (2)

(1)

Example Wiring Diagram

1
2
3

FIG. 8

332305B

Installation

Alarm Outputs
DC example shown. See Technical Data, page 72 for ratings.

Connector on Housing

Pin-out

(1)

1 N.O.

(3)

2 N.C.
3 COM
4 Not Used

(4)

(2)

Example Wiring Diagram

1 A Fuse

G3
Alarm +9-30V
1 Amp Max

1
2
3
4
Switch closes on alarm
(shown in non-alarm position)

FIG. 9

332305B

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. 11

FIG. 10

332305B

Installation

Part No. 124594: 4 Pin Eurofast Field
Wireable Connector

Part No. 124595: 5 Pin Eurofast Field
Wireable Connector

FIG. 12

FIG. 13

332305B

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. 14 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. 14

332305B

•

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 66.

•

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 71.

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 23.

•

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. 15

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. 15).

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 use more than 2 spacers to adjust output volume.

•

Do not overfill (FIG. 17).

•

Do not operate G3 without reservoir attached.

Output Volume / Minute
No. Spacers

cubic inches

cubic cm

0.12

0.18

0.25

Loading Grease
To ensure optimal performance from the G3:

•

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.

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.

332305B

Setup

Models without a follower plate:

To start the pump press the manual run
button.

1. Connect fill hose to inlet fitting (FIG. 16).

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.

D
vent hole

FIG. 16
2. For higher viscosity fluids, start pump to rotate stirring paddle during fill to prevent air pockets from
forming in grease.
To start the pump press the manual run
button.

FIG. 18
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. 17
4. Remove fill hose.

Models with a follower plate:
1. Connect fill hose to inlet fitting (FIG. 16).
2. For higher viscosity fluids, start pump to rotate stirring paddle during fill to prevent air pockets from
forming in grease.

332305B

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. 19).

•

Do not operate G3 without reservoir attached.

•

Only use oils with viscosity at least 40 cSt.
FIG. 20
a

2. Only run pump until air is no longer dispensed with
the lubricant coming out of element fitting (FIG. 21).
b

FIG. 19
1. Remove fill cap (a).
2. 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.

FIG. 21
3. Tighten pump element fitting using two wrenches
working in opposite directions (FIG. 20).

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 output volume

332305B

Quick Setup Guide

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332305B

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Max Model Setup

Max Model Setup
Control Panel Overview (FIG. 22)
NOTE: Programming instructions begin on page 29.
OFF TIME/BACKUP TIME
DISPLAY

•
ON TIME/BACKUP TIME

•

LED lights when ON
Time/Backup Time is running.
Display shows time as MM:SS
(minutes and seconds).
i.e., 08:30 is 8 minutes: 30 seconds.
Sets the limits for the amount
of time to complete a cycle or
build up pressure before a
warning is activated.
Counts down from a set time to
zero.

•

•
•

A blinking LED under HH, MM, SS
or ## identifies type of measurement
unit you are setting; i.e., HH is
hours.
A blinking number on the display
indicates the G3 is in SETUP
MODE.
In RUN MODE displayed numbers
count up or down. See Time ON and
Time OFF.

•

LED lights when OFF
Time/Backup Time is used to control Pump OFF function.
Value is entered in HH:M.

•
•

Displays in HH:MM (hours and
minutes) when > 1 hour.
Times pump rest between cycles.

•
•

Counts down from set time to
zero.
Can be set up to use as a backup
for Machine Count control.

•

ALARM ICONS
LED next to icon lights when a
fault / warning event occurs
during a run cycle. See page 57
for a complete description of
these alarm scenarios.

CYCLE / PRESSURE SETUP

•

Sets either Cycle (C) or Pressure
(P) Monitoring limits for up to 3
sensors.
Each sensor is set up and controlled independently.

•

PIN ICON

•
MACHINE COUNT

•

LED lights when Machine Count
is used to control Pump OFF
function.
Counts independent machine
operations with a sensor to control Pump Off duration.
Time OFF function can be used
as a backup for Machine Count.

•
•

LEFT DIRECTION ARROW /
RESET

•
•
•

In ADVANCED and SETUP
MODES, moves cursor in display one field to the left.
In RUN MODE: single press
clears warning.
In ALARM MODE: pressing and
holding for 3 seconds clears
fault / warning and switches
cycle to OFF MODE.

•

LED next to icon lights indicating PIN is required to
enter setup.
In SETUP MODE LED
lights when setting up the
PIN.

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

UP and DOWN ARROW

RIGHT DIRECTION ARROW /
MANUAL RUN / ENTER

•

Hold both the UP and DOWN ARROW buttons down together for 3 seconds to enter
SETUP MODE.
In SETUP MODE, increases or decreases
number values shown in display.

•

In SETUP MODE, saves
entry, moves cursor in display
one field to the right or to the
next setup step.
In RUN MODE starts a manual run cycle.

FIG. 22
28

332305B

Max Model Setup

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

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

•

In RUN MODE numbers on the display do not blink.

•

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

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

1. Press both the UP and
DOWN ARROW buttons for 3
seconds.
2. The LED next to the LOCK ICON on
the display lights and the 4 zeros
appear on the display indicating the
system requires a PIN Code entry to run the G3 in
SETUP MODE.
3. The cursor is automatically
positioned to enter the first
character of the PIN Code.
Use the UP and DOWN
ARROW buttons to move up
and down through the numbers 0-9 until the first
number in the PIN code is displayed in the field.
4. Press the ENTER button to set the number. The cursor automatically moves to
the next number field.
5. Repeat steps 3 and 4 for each PIN Code prompt
field.
If the PIN Code you entered is correct, the first editable
character on the display will flash.
NOTE: A blinking field on the display indicates the G3 is
in SETUP MODE. In RUN MODE numbers on the display will not blink.

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

Entering a PIN Code to Access Setup Mode
The G3 controller does not require a user to provide a
PIN code to access the programming features of the
unit. However, Graco understands that some users may
want to protect the programming settings and therefore,
an option for adding PIN Code authorization is available.
The instructions for setting up PIN Code Authorization
are provided in the Advanced Programming section of
this manual. See page 46.
To enter the PIN Code:
332305B

Max Model Setup

Setting the Real Time Clock
DMS

™

the list of months until the current month is displayed in the field.

Equipped Models Only

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

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 Year:
•

•

The year displays.
The first programmable character, the
decade, blinks indicating the device is
ready to program the
decade digit of the year.
The LED under the # sign lights while setting the
year.

1. Use the UP and DOWN arrow buttons to move up and down through
the number 0-9 until the number
for the current decade is displayed
in the field.
2. Press the ENTER button to set the
decade number. The cursor automatically moves to the next field, the
year number.
3. Use the UP and DOWN arrow buttons to move up and down through
the number 0-9 until the number
for the current year is displayed in
the field.
4. Press the ENTER button to set the
year number.

Enter the 2-digit Date:
The first programmable
character of the 2-digit
date blinks indicating the
device is ready to program the first digit of the
date.
The LED under the # sign lights while setting the date.
1. Use the UP and DOWN ARROW
buttons to move up and down
through the numbers 0-3 until the
first digit of the date is displayed in
the field.
2. Press the ENTER button to accept
the selection. The cursor automatically moves to the second digit of
the date.
3. Use the UP and DOWN ARROW
buttons to move up and down
through the numbers 0-9 until the
second digit of the date is displayed in the field.
4. Press the ENTER button to set the
date.
The time displays indicating the G3 is now ready to
program the time.

The 3-character month displays indicating the G3 is
now ready to program the month.

Enter the Month:

1. Set the 3 character month by using
the UP and DOWN ARROW buttons to move up and down through

Enter the Time:
•

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

•

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

•

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

332305B

Max Model Setup

•

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

•

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

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

•

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

2. Press the ENTER button to set the
number.

Cycle (C1, C2, C3) Setup

•

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

•

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

3. Use the UP and DOWN ARROW buttons to move
up and down through the numbers 0-9 until the
desired number for the second HH number field
appears.
4. Press the ENTER button to set the
number.
5. The next number field to the right blinks and the
LED under the MM lights indicating the G3 is ready
to program the minutes fields.
6. Repeat steps 1-4 to set the minutes (MM) fields.
7. After pressing the ENTER button to
set the time, the programmed Time
information is saved.

Programming ON Duration
•

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

•

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

C1, C2, C3 - Completing a specific number of
cycles measured by an external prox/cycle
switch

•

P1, P2, P3 - Reaching a specific pressure
threshold measured by an external pressure
switch - OR,

•

OFF - A specific duration of time elapses.

332305B

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

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

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

1. Use UP or DOWN arrow button to toggle display between
OFF / C1 / P1 on the display.
2. When C1 is
on display,
press the
ENTER
button to
save selection and begin programming Cycle data.
•

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

•

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

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

Max Model Setup

4. The cycle field is a 2 digit number.
When the correct first numeral of the
number displays, press the ENTER button to save the number. The cursor
automatically moves to the second number field.
NOTE: A leading zero (0) must be entered in the
first field if the number of cycles is fewer than 10.
5. Press the ENTER button, to save the C1
information.
•

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

3. If your G3 comes equipped with more than one sensor input, you will automatically be prompted to
begin selecting pump control type for the next sensor. Repeat steps 1 - 2 to program P2 and P3.
If P1 / P2 / P3 is selected the vent valve time is
automatically set to 5 minutes. If the unit is used in
an injector based system and a sensor input is not
used, the user must update the vent valve time in
advanced programming. (See Advanced Programming, A-3 Vent Valve Time, page 47.)

Input Not Used
Select OFF if your system does not use the applicable
input.
1. Use UP or DOWN arrow button to toggle between OFF /
C1 / P1 on the display.

NOTE: If C / P2 and C / P3 are not used, the default
OFF setting must be entered instead.
6. After you set the last field and press the
ENTER button, the G3 saves the Cycle
information and moves to setting
Backup Time, page 34.

Pressure Control (P1, P2, P3) Setup
•

•

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

If the sensor inputs are available and none are used in
the ON Mode, the definition of the entered time is ON
TIME.

Pressure control is an ON / OFF selection only.

Model G3-G-24MX-2LFL00-10CV00R0 has 1 sensor,
only C/P1 is available for programming.

1. Use the UP or DOWN arrow
button to toggle between OFF
/ C1/ P1.
2. When P1
displays,
press
ENTER
button to
save
selection.
32

2. When
OFF is on
the display,
press the
ENTER
button to save selection.

Examples:
Model G3-G-24MX-2LFL00-1DMVA2R3 has 4 sensors,
so C/P1, C/P2, and C/P3 and Machine Count can all be
programmed.

Backup Time
In both Cycle and Pressure Modes, a maximum run
Time (Backup Time) for the lubrication period must be
set up. If this Time expires before the lubrication is completed an alarm/warning is triggered and the pump
stops.

332305B

Max Model Setup

To determine the Backup Time, Graco recommends the
user verify the length of time it takes to complete a typical cycle and double that value (to a maximum of 30
minutes).

6. After pressing the ENTER button to set
the last SS field, all the programmed ON
Time information is saved.
The G3 automatically switches to the OFF Time
SETUP MODE.

Backup Time is setup after Cycle or Pressure Sensor
Setup is complete.
NOTE:

ON Time
•

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

•

The LED next to the clock in the ON field lights, indicating the Backup Time is being programmed.

•

BACKUP (ON) Time is set as minutes and seconds
(MM:SS) only.

•

ON Time is set in Minutes and Seconds (MM: SS).

•

The small flashing LED under the MM indicates you
are setting minutes.

•

The first field (left side of display) blinks indicating
the device is ready for you to begin programming.

An LED flashes under
either MM when programming minutes
OR SS when programming seconds.

Programming Backup Time
NOTE: When programming a time of less than 10 minutes you must program the leading zero in the first number field and press the ENTER button to save the zero
selection.
1. To set the ON Time use the
UP or DOWN ARROW button
to scroll through numerals 0
to 5 until the desired number
appears in the first MM (minutes) field.
2. Press the ENTER button to lock in the
selection. The next MM number field to
the right flashes indicating it is ready for
programming.

•

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

•

The total amount of ON Time cannot
exceed 30 minutes. If a value greater
than 30 minutes is entered, the RED
alarm LED lights and the value must
be updated.
If this time does not meet the application needs,
contact Graco Customer Support.

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.

Programming ON Time

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

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

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

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

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

332305B

Max Model Setup

2. Press the ENTER button to lock in the
selection. The next MM number field to
the right flashes indicating it is ready for
programming.
3. Use the UP or DOWN
ARROW button to scroll
through numerals 0 to 9 until
the desired number appears
in the second MM number
field.
4. Press the ENTER button to lock in the
selection.
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.

indicating you are now in the Machine Count setup
mode.
2. Press the UP or DOWN
ARROW button to move up
or down through number 0-9.
3. When the correct number displays,
press the ENTER button to set the number.
NOTE: If the machine count input is available on the unit
and not used, the value MUST be set to zero (0).
4. Repeat 2 - 3 to set the remaining fields.
NOTE: After the Machine Count value is entered, the
G3 can be programmed to backup the machine count
input with time.
Backup Time Setup
1. The OFF Time LED lights.

The G3 automatically switches to the OFF Time
SETUP MODE.

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

OFF displays.

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

•

Machine Count switch activation, or

•

Machine Count activations limited by a maximum Time, or

•

A specific set amount of Time (similar to Time
Mode).

3. Press the ENTER button to set the
selection.

•

If the machine count sensor input is available
and not used in the OFF Mode, the definition of
the entered time is OFF TIME.

Backup Time
•

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

•

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

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

332305B

Max Model Setup

•

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

5. Repeat steps 1 - 4 to set the next MM (minutes)
fields.
OR

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

6. After pressing the ENTER button to set
the last MM field, the OFF Time information is saved.
7. After selecting ON, refer to page 32.
NOTE: Backup time can be set in HH:MM for the
machine count input.

OFF Time

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

•

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

•

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

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

•

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

Programming Backup Time
NOTE: When programming a Backup Time of less than
10 hours you must program a leading zero in the first
number field and press the ENTER button to save the
zero selection.
1. To set the Backup Time use
the UP or DOWN ARROW
button to scroll through
numerals 0 to 9 until the
desired number appears in
the first HH (hour) field.
2. Press the ENTER button to lock in the
selection. The next HH number field to
the right flashes indicating it is ready for
programming.
3. Use the UP or DOWN
ARROW button to scroll
through numerals 0 to 9 until
the desired number appears
in the second HH number
field.
4. Press the ENTER button to lock in the
selection.

•

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

•

The total amount of OFF Time must be
at least twice as long as the programmed ON Time. If a value less
than twice the ON Time is entered, the
RED alarm LED lights and the value must be
updated.
If this time does not meet the application needs,
contact Graco Customer Support.

Programming OFF Time
NOTE: When programming a time of less than 10
hours you must program a leading zero in the first
number field and press the ENTER button to save the
zero selection.

The next number field to the right
flashes and the LED lights under MM; indicating it is
ready to program the minutes fields.
332305B

Max Model Setup

1. To set the OFF Time use the
UP or DOWN ARROW button
to scroll through numerals 0
to 9 until the desired number
appears in the first HH (hour)
field.
2. Press the ENTER button to lock in the
selection. The next HH number field to
the right flashes indicating it is ready for
programming.
3. Use the UP or DOWN
ARROW button to scroll
through numerals 0 to 9 until
the desired number appears
in the second HH number
field.
4. Press the ENTER button to lock in the
selection.
The next number field to the right
flashes and the LED lights under MM; indicating it is
ready to program the minutes fields.
5. Repeat steps 1 - 4 to set the next MM (minutes)
fields.
6. After pressing the ENTER button to set
the last MM field, the OFF Time information is saved.

Prelube
The Prelube function determines operation of the pump
when power is applied. It can be set to OFF or ON.
OFF (default) - The unit resumes its lubrication cycle at
the point it was at when power was removed.
ON - The unit begins a pump cycle.
Setting Prelube
1. After you set the OFF Time information and press
the ENTER button, the G3 automatically switches to
the Prelube Delay setup.
Notice the LED next to the prelube
icon on the G3 display lights indicating you are now in the Prelube setup
mode.

2. OFF displays. If you
want the prelube
cycle to begin immediately, leave this set
to OFF.
3. Press the ENTER button to set the
selection.
4. If you want to set a
prelube delay time,
press the DOWN
ARROW button to
change OFF to ON
on the display.

Prelube Delay
Prelube Delay can be entered to delay the start of the
pump’s cycle on power up. If prelube is set to ON, a prelube delay time in MM:SS must be entered. By default,
the delay is set to 0 (begin an ON cycle immediately).
Delaying the prelube function may be desired if other
critical functions or systems of your machine or vehicle
are also coming on line during power up.
1. Prelube Delay is set in
MM:SS (minutes and seconds). To set the time use the
UP or DOWN ARROW button
to scroll through numerals 0
to 5 until the desired number
appears in the first MM (minutes) field.
The maximum length of time Prelube Delay can be
set to is 59:59 (59 minutes:59 seconds).
2. Press the ENTER button to lock in the
selection. The next MM number field to
the right flashes indicating it is ready for
programming.
3. Use the UP or DOWN
ARROW button to scroll
through numerals 0 to 9 until
the desired number appears
in the second MM number
field.
4. Press the ENTER button to lock in the
selection.
The next number field to the right

332305B

Max Model Setup

flashes and the LED lights under SS; indicating it is
ready to program the seconds fields.
5. Repeat steps 1 - 4 to set the SS (seconds) fields.
6. After pressing the ENTER button to set
the last SS field the G3 automatically
switches to the RUN MODE.

DMS

™

Models Only

Downloading Data
1. Plug the USB flash drive into the USB port.
NOTE: The G3 pump stops pumping as soon as the
USB flash drive is plugged into it.
2. The system automatically begins downloading data
to the USB drive.
3. “data” is displayed while the system
is downloading files.
4. When download is finished, “done” is
displayed.
5. G3 pump restarts cycle in the OFF mode.
6. Remove the USB flash drive.

5. G3 pump restarts cycle in the OFF mode.
6. After the download is complete, press and hold the UP
and DOWN ARROW button
for 3 seconds to store the current setup to the USB flash
drive.
7. “data” is displayed while the unit is
downloading and storing the configuration on the USB drive.
8. When configuration is stored, “done”
is displayed.
9. G3 pump restarts cycle in the OFF mode.
10. Remove the USB flash drive.

Uploading Pump Program
Settings to the Pump
1. Plug the USB flash drive into the USB port.
NOTE:
•

The USB flash drive must contain file
GRACO/G3Config/g3config.bin.

•

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

Storing Pump Program Settings
to the Flash Drive

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

The pump program settings file is named:

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

GRACO/G3Config/g3config.bin. This file cannot be
modified. Modification of the file or file name may cause
it to be unusable.

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

1. Plug the USB flash drive into the USB port.
NOTE: The G3 pump stops pumping as soon as the
USB flash drive is plugged into it.
2. The system automatically begins downloading data
to the USB drive.
3. “data” is displayed while the system
is downloading files.
4. When download is finished, “done” is
displayed.

332305B

5. G3 pump restarts cycle in the OFF mode.
6. After the download is complete, press and hold the
RESET button and UP
ARROW button for 3 seconds
to upload the setup stored in the USB flash drive.
7. “data” is displayed while the unit is
uploading the configuration data.
8. When upload is finished, “done” is
displayed.

Max Model Setup

9. G3 pump restarts cycle in the OFF mode.
10. Remove the USB flash drive.
11. After the USB flash drive is
removed, press and hold the
UP and DOWN ARROW buttons for 3 seconds to enter
the SETUP MODE (see
Entering Setup Mode, page 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 ARROW button after viewing
the DMS ID number.

332305B

Operation / Data Log

Operation / Data Log
During operation the G3 Pump stores information as
Log and Summary Files.
Logs contain the following information:
•

Log Name

•

DMS ID Number

•

Current Software Graco Part Number

•

Current Software Version

•

Date and Time of Upload

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

Sample System Event Log
Example Event Log 1: Pump cycle of a divider valve
system with a proximity switch set to detect 5 divider
valve cycles.
G3 System Event Log
DMS ID Number: 0025 (see page 38)
Software Part Number: 16F821
Software Version: 1019
09/29/2010
14:1400
Date
9/29/2010
9/29/2010
9/29/2010
9/29/2010
9/29/2010
9/29/2010
9/29/2010

Time
14:13:02
14:13:02
14:12:39
14:12:34
14:12:28
14:12:23
14:12:17

Description
Pump Run Off
C1 Cycle Completed
C1 Cycle Detected
C1 Cycle Detected
C1 Cycle Detected
C1 Cycle Detected
Pump Run On

The log file is stored in a folder structure created by the
pump DMS ID and download date. If multiple downloads
are done on the same date, the existing files will be written over.
The folder structure is as follows:
GRACO/G3_{DMS_id}/{download date - YYYYmmDD}/EVENTLOG.CSV
Example: GRACO/G3_00025/20100911/EVENTLOG.CSV.

332305B

Operation / Data Log

Example Event Log 2: Pump cycle of an injector valve
system with a pressure switch feedback.
Date
9/29/2010
9/29/2010
9/29/2010
9/29/2010
9/29/2010

Time
13:28:12
13:23:12
13:23:11
13:23:11
13:22:20

Description
Venting Completed
Venting Detected
Pump Run Off
P1 Pressure Completed
Pump Run On

Venting Detected

In an injector system, the pump on cycle
has completed and the system is currently venting pressure through the vent
valve.

Prelube Initiated

The pump has entered a prelube delay
after powering up.

Prelube Completed

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

Successful Pin
Code Entry

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

Common System Events are listed below.
Pump Run On

The pump entered an on cycle and is
operating and dispensing material.

Pump Run Off

The pump entered an off cycle and is
not dispensing.

Pump Run Cancelled

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

G3 Power On

The pump powered on.

G3 Power Off

The pump powered off.

Program Variable
Change

The setup mode was entered.

C1 Cycle Detected

The system is set up to monitor a proximity switch on a divider valve using the
sensor input (C1, C2, and/or C3) and
has detected one divider valve cycle.

C2 Cycle Detected
C3 Cycle Detected
C1 Cycle Completed
C2 Cycle Completed
C3 Cycle Completed
P1 Pressure Completed
P2 Pressure Completed
P3 Pressure Completed
Machine Count
Completed

The system is set up to monitor a proximity switch on a divider valve using the
sensor input (C1, C2, and/or C3) and
has achieved the number of counts
required by the system for that input,
completing a pump on cycle.
The system is set up to monitor a pressure switch for an injector system using
sensor input (P1, P2, and/or P3), the
system has achieved pressure and the
switch has activated, completing a
pump on cycle.
The system is set up to monitor a sensor on the equipment being lubricated
using the machine count input and has
achieved the number of counts required
by the system for that input, completing
a pump off cycle and initiating a pump
on cycle.

Local Manual Run
Initiated

The manual run button was pressed,
initiating a pump on cycle.

Remote Manual
Run Initiated

The remote manual run button was
pressed initiating a pump on cycle.

Error Log
The Error Log lists Set Time and Clear Time for the last
400 faults and warnings. The most recent event is listed
first.
The log file is stored as:
GRACO/G3_{DMS_id}/{download date - YYYYmmDD}/ERRORLOG.CSV
Example: GRACO/G3_00025/20100911/ERRORLOG.CSV.

Sample Error Log
G3 Error Log
DMS ID Number: 00025 (see page 38)
Software Part Number:16F821
Software Version:0205
12/31/2015
23:04:00
Date
Time
12/31/2015 23:03:54
12/31/2015 23:03:42
12/31/2015 23:03:32
12/31/2015 23:03:22
12/31/2015 23:03:22
12/31/2015 23:03:19
12/31/2015 23:03:19
12/31/2015 23:02:20
12/31/2015 23:02:11

Description
Low Level Cleared
Low Level Fault
Low Level Warning
P2 Not Detected Cleared
C1 Not Detected Cleared
P2 Not Detected
C1 Not Detected
Machine Count Not Detected
Machine Count Not Detected

332305B

Operation / Data Log

Common Error Log entries are listed below.
Software Fault

An internal software error
occurred. Contact Graco Customer Service.

Low Level Warning

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

Low Level Fault

The alarm time in low level
warning has elapsed. The unit
will not pump until the reservoir
is filled and the fault is cleared.

Cycle 1 Not Detected

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

Cycle 2 Not Detected
Cycle 3 Not Detected

Pressure 1 Not
Detected
Pressure 2 Not
Detected

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

Pressure 3 Not
Detected
System Already Pressurized 1
System Already Pressurized 2
System Already Pressurized 3

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

Machine Count Sensor The specified number of
Failure
machine count input activations was not received within
the designated backup time.
Motor Overcurrent

332305B

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 operation at excessive motor currents will cause degradation in
pump life.

High Temperature
Warning

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

Low Temperature
Warning

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

USB Unable to Mount

The USB flash drive that was
installed was unable to connect
and communicate with the
pump.

USB Unsupported
Device

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

USB File Not Found

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

USB Folder Navigation The pump program setting file
was not found or created correctly. Restore the setting file
to the flash drive.
USB Invalid File

The pump program settings file
was not found or created correctly. Restore the setting file
to the flash drive.

Failed Pin Code Entry

A failed attempt was made to
enter the pin code password.

Operation / Data Log

Functional Summary
The Functional Summary contains two types of data.
•

The first report type, labeled User under the Type
heading in the first column of the Sample Functional
Summary, only provides data compiled since the
last time the Functional Summary was reset through
present day (see A6 - Clearing the Functional and
Technical User Summary, page 49).

•

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

GRACO/G3_{DMS_id}/{download date - YYYYmmDD}/FUNCSUM.CSV
Example: GRACO/G3_00025/20100911/FUNCSUM.CSV

Sample Functional Summary
(see page 38)

332305B

Operation / Data Log

Common Functional Summary Data entries are listed
below.
Number of Cycles

The number of lubrication cycles
the unit has started.

Total Run Hours

Total amount of hours the pump
has been in the ON mode of the
ON/OFF cycle.

Total Powered On Hours

Total number of hours that the
unit has been powered on.

Local Manual Run

The number of times the manual
run button was pressed.

Remote Manual Run

The number of times the remote
manual run button was pressed.

Average Run Time

The average amount of time per
lubrication cycle that the pump
has been running (MM:SS).

Average Cycle 1 Time

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

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 faults.

Total Cycle Pressure
Faults

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

Total Other Faults

Faults other than low level or
sensor feedback.

Total Fault Hours

Number of hours the system has
been powered on in fault mode.

Total Low Level Warnings

Number of low level warning
conditions.

Total Cycle Pressure
Warnings

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

Total Other Warnings

All other warnings including temperature and motor current.

332305B

Operation / Data Log

Technical Summary
The Technical Summary contains two types of data.
•

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

Common Technical Summary Data entries are listed
below.
Average Input Board
Voltage (DC)

The average input voltage measured by the internal circuit board.

Peak Input Board Voltage (DC)

The peak input voltage measured
by the internal circuit board.

Average Motor Current

The average motor current measured by the unit.

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

Peak Motor Current

The peak motor current measured by the unit.

Average Internal Temperature

The average internal temperature seen by the unit.

This is very similar to an odometer in your car.

Peak Internal Temperature

The peak internal temperature
seen by the unit.

Low Internal Temperature

The lowest internal temperature
seen by the unit.

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

Example: GRACO/G3_00025/20100911/TECHSUM.CSV

The log file is stored as:
GRACO/G3_{DMS_id}/{download date - YYYYmmDD}/TECHSUM.CSV

Sample Technical Summary
G3 Technical Summary
DMS ID Number: 00025 (see page 38)
Software Part Number:16F821
Software Version: 0205
12/27/2010
9:50:51
Latest Values
Temp
Voltage
31C
23.877

Type

User
Factory

Average
Start Date Average Peak
Average Peak
Internal
Board
Motor
Motor
Board
Voltage
Current
Current
Temp
Voltage
12/21/2010
23.877
23.877
0.062
0.06230C
9/30/2010
22.804
23.877
1.091
0.36233C

Peak
Internal
Temp
35C
42C

Low
Internal
Temp
28C
-10C

332305B

Advanced Programming

Advanced Programming
There are 7 Advanced Programming options. The following Table Identifies each option and when it is used.
Advanced
Option

Model

Max

Setting

Format/ Description

Why Use This?

Lockout
Code
(Optional)
Low Level
Alarm Time

Secures setup modes with
PIN

Prevents unauthorized users to adjusting
settings.

Vent Valve
Time

To accommodate most lubrication situations, a conservative amount of time is programmed between the low level warning
and fault to help protect unit from running
dry. If necessary the amount of time the
unit runs before stopping due to a low level
fault can be adjusted.
• In an injector based system that does not
MM:SS (minutes:seconds)
use a sensor for feedback, determines
sets amount of time vent
the amount of time the system vents.
valve stays open after Pump
• Vent time can be modified.
ON Mode.
MM:SS (minutes:seconds)
sets amount of time
between Low Level Warning
to Low Level Fault.
Default = 3 minutes

Default = 5 minutes
Establishes the number of times the unit
Alarm Retry Sets number of automatic
retries after a Cycle or Pres- automatically retries lubricating after a
cycle or pressure alarm to determine if a
sure Alarm.
temporary or false signal can be cleared.
Default = 0
Active
Uses alarm output to determine if a unit has
Changes alarm output
Alarm
behavior.
an alarm AND/OR loses power.
Default = OFF

The output turns ON when power is
applied. It turns OFF when power is lost or
an alarm occurs.
Normal operation (OFF) will only activate
alarm output in an alarm condition when
power is on.
Can change (set to ON) to activate alarm
with power ON and deactivate with power
OFF OR warning.

DMS™
Equipped
Models

332305B

Max

Functional
and Technical User
Summary
Reset
Constant
Alarm Output on Fault

Clears the Functional and
Technical User Summaries

Changes alarm output
behavior.
Default = OFF

Used to manage power outage.
Allows user to track lube events from a specific point (reset), i.e. a month to month
evaluation.

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

Advanced Programming

Entering a PIN Code for the First Time
A1 - Setting Up PIN Code
A PIN Code can be programmed into the G3 to protect
the settings from inadvertently being changed by unauthorized users.

1. The cursor is automatically
positioned to enter the first
character of the PIN Code.
Use the UP and DOWN
ARROW buttons to move up
and down through the numbers 0-9 until the first
number in the PIN code is displayed in the field.

1. Press the UP ARROW button for 10
seconds.

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

The LED next to the LOCK ICON on the
display lights, indicating you have entered
the PIN Mode.

3. Repeat steps 1 and 2 for each PIN Code prompt
field.

2. The word OFF appears in the
display. Press the UP or
DOWN ARROW button to
change this to ON.
3. Press the ENTER button to enter the
PIN Code.
4. The cursor automatically is
positioned to entered the first
character of the PIN Code.
Use the UP and DOWN
ARROW buttons to move up
and down through the numbers 0-9 until the first
number in the PIN code is displayed in the field.

If the PIN Code you entered is correct, the first editable
character on the display will flash.

Selecting Advanced Setup Options
1. Press the UP or DOWN
ARROW button to move up
or down through Advanced
Options A1 - A7.
2. Press the ENTER button to set the
selection.

5. Press the ENTER button to set the
number. The cursor automatically
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 seconds.
If the G3 was previously set up to require a
PIN Code, the LED next to the LOCK ICON lights, indicating a PIN Code is required.

332305B

Advanced Programming

A2 - Low Level Alarm Time
Pump ON mode only.
Programs the amount of time in MM: SS (minutes and
seconds) the pump can run between a Low Level Warning and a Low Level Fault to help protect unit from running dry.
The maximum recommended length of time is 3:00 minutes.
Fault, and Low Level LED illuminate. (Max Model Display shown in illustration below).

3. Use the UP or DOWN
ARROW button to scroll
through numerals 0 to 9 until
the desired number appears
in the second MM number
field.
4. Press the ENTER button to lock in the
selection.
The next number field to the right
flashes and the LED lights under SS; indicating it is
ready to program the seconds fields.
5. Repeat steps 1 - 4 to set the SS (seconds) fields.
6. After pressing the ENTER button to set
the last SS field, all the programmed ON
Time information is saved.
Unit exits Advanced Programming.

A3 - Vent Valve Time
The Vent Valve Time is the amount of time the vent
valve stays open after a cycle is completed.
The recommended Vent Valve Time is 5 minutes.
To bypass the Vent Valve Time enter a value of 00:00.

FIG. 23

Vent Valve time must be less than the programmed OFF
time (page 35). If it is not set to a value less than the
programmed OFF time, the G3 will automatically adjust
the time to a value 2 seconds less than the set OFF
time.

NOTE: When programming a time of less than 10 minutes you must program a leading zero in the first number field and press the ENTER button to save the zero
selection.
1. To set the time use the UP or
DOWN ARROW button to
scroll through numerals 0 to 9
until the desired number
appears in the first MM (minutes) field.
2. Press the ENTER button to lock in the
selection. The next MM number field to
the right flashes indicating it is ready for
programming.

332305B

Advanced Programming

To set Vent Valve Time:
NOTE:
•

The LED next to the clock in the OFF
field lights and P1, P2, and P3, indicating the Vent Valve Time is being
programmed.

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

A-4 Alarm Retry

•

Time is set as minutes and seconds (MM:SS) only.

•

The small flashing
LED under the MM
indicates you are
setting Minutes.

•

The first field (left
side of display) blinks
indicating the device
is ready for you to
begin programming.

•

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

Programs the number of times G3 will automatically
retry running a lubrication cycle after a cycle or pressure
alarm activates. The default setting is 0. For assistance
determining a reasonable number of Alarm Retries to
program for your application, contact Graco Customer
Service or your local Graco distributor.
1, 2, and 3 and Fault LED’s illuminate.

1. To set the Time use the UP or DOWN ARROW button to scroll through numerals 0 to 5 until the
desired number appears in the first minute field.
2. Press the ENTER button to lock in the
selection. The next minute field to the
right flashes indicating it is ready for
programming.
3. Use the UP or DOWN
ARROW button to scroll
through numerals 0 to 9 until
the desired number appears
in the second minute field.
4. Press the ENTER button to lock in the
selection.
5. The next number field
to the right flashes
and the LED lights
under SS; indicating
it is ready to program
the Seconds fields.

FIG. 24
To set the Alarm Retry:
1. The default value
0000 appears in the
display.

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

6. Repeat steps 1 - 4 to set the MM (seconds) fields.
48

332305B

Advanced Programming

3. When the correct number displays,
press the ENTER button to set the number.
4. Repeat 2 - 3 to set the remaining fields.
5. Press the ENTER button to exit
Advanced Programming.

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.

A-5 Active Alarm
Changes the alarm output behavior. Uses output to
determine if a fault has occurred.
Fault and ON LED’s illuminate.

FIG. 26

FIG. 25

1. The default OFF displays.

1. Press the UP or DOWN
ARROW button to move
through Advanced Options
until Advanced Option A6 is
displayed.
2. Press the ENTER button.
3. “Data” displays.

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

4. Press the RESET button. “Reset” displays.
The summary data is
cleared.
5. Press the RESET or
ENTER button to exit.

332305B

Advanced Programming

A-7- Constant Alarm Output on Fault
This function changes the behavior of the alarm output
in a fault from either toggling once every second
(default) or steady on.
Fault and Warning LEDs Illuminate

OFF

MM : SS

HH : MM

C
P1
C
P2

C
P3

123

FIG. 27

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.

332305B

Run Mode

•

Time Control
After setup is complete, the G3 automatically begins to
run the OFF Time sequence (FIG. 28).
•

When the OFF Time count reaches zero, the G3
Automatic Lubrication Pump turns the pump on and
it runs for the programmed ON Time cycle (FIG. 29).
(Notice the ON Time LED is now illuminated on the
display.)

•

The G3 runs the programmed OFF sequence.

The example shown in FIG. 29 shows an ON Time
of 8 minutes and 42 seconds before the lubrication
cycle ends.

(Notice the OFF Time LED on the display lights and
the OFF Time counts down on the display.)
HH

•

The example shown in FIG. 28 shows an OFF Time
of 1 hour and 32 minutes before the lubrication
cycle begins.

OFF

MM : SS

HH : MM

!
C
P1

OFF

MM : SS

HH : MM

C
P2

C
P3

123

C
P1
C
P2

C
P3

123

FIG. 29
•

FIG. 28

This sequence repeats itself until the device is
reprogrammed or an alarm occurs.
•

332305B

When the ON Time count reaches zero, the pump
shuts off again and the system again runs OFF
Time cycle and the OFF Time LED is now again illuminated (FIG. 28).

If power to the pump is lost during a lubrication
cycle, when power is restored the pump will resume
the cycle with the same amount of time remaining in
the cycle as when the power was lost.

Run Mode

Lubrication Mode (Pump ON) Controls
In Max models the Lubrication Mode (Pump ON) can be
controlled by either cycle and/or pressure sensors.
If cycle and/or pressure controls have been set to something other than OFF the display will alternate between
cycles (C1, C2, C3) and/or active sensors (P1, P2, P3)
and Backup Time.

Pressure Control
•

A single triggered count in a pressure based
system (P1). Typically a pressure switch on the
end of a line of injectors.

•

The LED next to the appropriate sensor (C/P1,
C/P2, C/P3) illuminates (FIG. 31 and FIG. 32).

•

The display indicates the sensor (P1, P2, P3)
and whether the pressure switch for that sensor
has been triggered or not.

If cycle or pressure controls have been set to OFF then
the Lubrication Mode (Pump ON) will be controlled by
On Time (see Time Control, page 51).

- 01 = pressure switch has not been triggered
- 00 = pressure switch is triggered.

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

The example shown in FIG. 31 shows sensor P1
with a pressure switch that has been triggered.

Cycle Control
•

A set number of triggered counts in a cycle
based system (C1). Typically a proximity switch
connected to a divider valve.

•

The LED next to the appropriate sensor (C/P1,
C/P2, C/P3) illuminates.

•

The display indicates the sensor (C1, C2, C3)
and the remaining cycles for that sensor (FIG.
30).

FIG. 32 (page 53) shows sensor P2 with a pressure switch that has NOT been triggered.

The example shown in FIG. 30 shows sensor C1
with 5 cycles remaining.

OFF

MM : SS

HH : MM

C
P1

OFF

MM : SS

HH : MM

C
P2

C
P3

123

FIG. 31

C
P1
C
P2

C
P3

123

FIG. 30

332305B

Run Mode

Backup Time

OFF

MM : SS

HH : MM

•

In both Cycle and Pressure modes a Backup
Time (maximum run time) has been set.

•

The LED(s) next to all programmed sensors
(C/P1, C/P2, C/P3) illuminate.

•

The display shows time remaining until a fault.
The example shown in FIG. 33 shows 14 minutes and 33 seconds left until the fault occurs.

•
C
P1
C
P2

C
P3

If all cycle and/or pressure requirements are
met the unit exits the lubrication cycle (Pump
ON) and enter the rest cycle (Pump OFF).

123
HH

FIG. 32

OFF

MM : SS

HH : MM

C
P1
C
P2

C
P3

123

FIG. 33
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 activated, the
display will only show the number of Machines Counts
remaining.

332305B

Run Mode

With machine count set, the Rest Cycle (Pump OFF) is
ended when the machine count reaches zero (0000).
Machine Count

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

•

A set number of triggered counts.

•

The LED next to 1-2-3 illuminates (FIG. 35).

•

The LED next to 1-2-3 illuminates (FIG. 34).

•

The display indicates the number of machine
counts remaining.

The display shows the amount of time remaining till a fault.

The example shown in FIG. 34 shows the
remaining number of machine counts is 0045.

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).

!
HH

OFF

MM : SS

HH : MM

OFF

MM : SS

HH : MM

C
P1

FIG. 34

C
P2

C
P3

C
P1

123

C
P2

C
P3

123

FIG. 35
OFF Time
In Max models if the Machine Count is set to 0000 then
Reset Mode (Pump OFF) is controlled with OFF Time
(see Time Control, page 51).

332305B

Run Mode

Additional Controls

Prelube

Venting

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

In Max models a Vent Time can be set using the
Advanced Programming mode (page 47). This is typically done in a Pressure Based System (P1) to allow
injectors to reset.

•

Power to the unit cycles OFF then ON.

•

Unit immediately begins a lubrication cycle.

•

Max Model - display shows Cycle/Pressure/Backup Time (See Max Model Lubrication
Mode Controls, page 52).

•

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

•

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

•

If Machine Count is set, the display will alternate
between machine counts remaining and backup
time (Max Model Rest Mode, page 53).

•

Power to the unit cycles OFF then ON.

•

If Machine Count has been set the LED next to
1-2-3 illuminates (FIG. 34, page 54).

•

Unit immediately begins the Prelube Delay
count down until the lubrication cycle begins.

•

If Machine Count has not been set the display
shows OFF Time (See Time Control, page 51).

•

The LED next to the clock in the OFF field is illuminated (FIG. 36).

•

If Machine Count has not been set the LED next
to the clock in the OFF field illuminates (See
Time Control, page 51).

•

The Prelube LED lights (FIG. 36).

•

The display shows time remaining until lubrication cycle begins. The example shown in FIG. 36
shows 8 minutes and 14 seconds left until a
lubrication cycle begins.

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

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

OFF

MM : SS

HH : MM

C
P1
C
P2

C
P3

123

FIG. 36

332305B

Run Mode

Manual Run Cycle
To run an extra (non-programmed) lubrication cycle, push the Manual Start button.

NOTE: Manual Run option is not available while unit is
in Vent Mode.

332305B

Alarms

Alarms
Any time a Fault / Warning occurs, a combination of LED’s will illuminate to notify you there is a problem and help
identify the kind of Fault / Warning has occurred.
•

Faults and Warnings will not automatically clear.

•

To clear an fault, press and hold the RESET button on the display button pad for 3 seconds.

•

To clear a warning press and immediately release the RESET button.

Fault / Warning Scenarios
The following pages describe the most likely fault / warnings you could receive.
Alarm Type
Low Level
Warning

What it Looks Like

OFF

MM : SS

HH : MM

What it Indicates
Solution
Add lubricant to reservoir.
Level of lubricant in
reservoir is low and additional lubricant needs to be After lubricant
is added,
added.
press the
Unit continues to operate RESET button to clear the warning.
as normal for a limited
period of time until a low
level alarm is triggered.

C
P1

332305B

C
P2

C
P3

123

Alarms

Low Level
Fault
HH

OFF

MM : SS

HH : MM

C
P1

Cycle /
Pressure
Warning

C
P2

C
P3

123

OFF

MM : SS

HH : MM

C
P1

C
P2

C
P3

123

Add lubricant to reservoir.
Level of lubricant in
reservoir is low and additional lubricant needs to be After lubricant is
added.
added press
and hold the
Unit stops pumping and
displays amount of accu- RESET button to clear
fault.
mulated time since the
alarm was triggered.
If repriming pump is
required, the low level
alarm time should be
decreased. See A-2:
Advanced Programming,
Low Level Alarm Time
page 47.

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

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

Unit will continue to operate for the number of lubrication cycles set by the
warning retry parameter
(see Advanced Programming, page 45).

Press the
RESET button to clear
warning.

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

332305B

Alarms

Cycle /
Pressure
Fault

OFF

MM : SS

HH : MM

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

C
P1
C
P2

C
P3

Examine system to determine if you have a
plugged or broken line or
other component failure,
i.e., divider valve, injector.
Press and
hold the
RESET button to clear
fault.

123

LED corresponding to the
affected sensor input
blinks.

Machine
Count Fault
HH

In pressure mode indicates that unit is over pressurized or a lubrication
cycle was not completed in
the user-defined amount of
time.

OFF

MM : SS

HH : MM

Could be more than one
sensor alarm at the same
time.
Unit has not received the Examine system to detercorrect number of machine mine if the machine sencounts in the user defined sor is operating properly.
Backup Time.
Press and
hold the
RESET button to clear
fault.

C
P1

332305B

C
P2

C
P3

123

Alarms

System
Fault
HH

OFF

MM : SS

HH : MM

An internal fault has
occurred.

Contact Graco Customer
Service.

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

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

C
P1

Motor Current Warning

C
P2

C
P3

123

OFF

MM : SS

HH : MM

C
P3

Examine pump to ensure
that it is rotating properly.
If necessary, contact
Graco Customer Service.

C
P1
C
P2

123

332305B

Alarms

Temperature Warning
HH

OFF

MM : SS

HH : MM

C
P1
C
P2

C
P3

123

USB Error
HH

The internal temperature of Ensure the unit is used in
the unit is out of its recom- the correct operating envimended operating range. ronment for the specific
temperature: -13° F to
Use of the unit outside of 158° F (-25° C to 70°C).
the recommended temperature range could cause If necessary contact
Graco Customer Service.
degraded system performance and possible damage.

OFF

MM : SS

HH : MM

An error occurred during a Read the TroubleshootDMS operation.
ing section of this manual
(page 62) for error numbers and fault descriptions.

C
P1

332305B

C
P2

C
P3

123

Troubleshooting

Problem
Unit does not power on

Cause
Incorrect/loose wiring
Tripped external fuse due to internal
component failure

Solution
Refer to Installation instructions,
page 8.
Contact Graco Customer Service.

Unit does not power on (DC models
only)

Tripped external fuse due to pumping Replace lubricant with pumpable
non-cold weather lubricant in cold
lubricant, rated for environmental
weather -13°F (-25°C)
conditions and application.

Unit does not power on (AC models
only)

Tripped internal power supply fuse
due to power supply failure

Replace fuse.

Can’t set desired ON/OFF times

Unit is not operating based on the
time that was programmed

Contact Graco Customer Service.

Maximum duty cycle is 33% (2 minutes OFF for each minute ON)

Adhere to allowable duty cycle. Contact Graco Customer Support if other
duty cycles are required for application.

Time entered was misinterpreted as
MM:SS instead of HH:MM (or visa
versa)

Verify the unit was programmed as
intended, referencing programming
instructions. Note the dot designation
for hours, minutes, seconds on the
top row of the display.

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 Ensure vent hole is not plugged.
filling
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 motor

Replace unit.

Air is trapped in the reservoir
between the follower plate and lubricant

Add grease following Loading
Grease instructions, page 24. Ensure
air is purged.

Follower plate is not going down

Pump takes several minutes before it Pumping non-cold weather lubricant
begins pumping at the highest pump in cold weather -13°F (-25°C)
volume setting (no stroke adjust
spacers installed)
Dim display, unit is not operating
Unit indicates a cycle or pressure
alarm before the lubrication cycle
could complete

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

Tripped internal, resettable fuse due
to internal component failure or sensor short circuit condition

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

The ON Time was not entered correctly

Refer to programming ON Time,
pages 31 and 52.

332305B

Troubleshooting

Problem

Cause

In an Injector System without sensor Vent valve time needs to be configfeedback, unit does not vent properly ured

Solution
Refer to Advanced Programming to
set ON Time, page 45.

Display acts erratically

Faulty cycle/pressure wiring connec- Unplug cycle/pressure cables from
tion to unit
G3. Plug cables in one at a time to
identify the faulty connection.

USB Error 00

Flash drive was removed during
operation

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

Flash drive unable to mount (initialize)

•

Pump program setting file not found
USB Error 11

Verify that the pump program setting
folder structure and file are stored
correctly on the flash drive. See Storing Pump Program Settings to the
Flash Drive, page 37 for instructions.

USB Error 12

Pump program settings directory not Verify that the pump program setting
found.
folder structure and file are stored
correctly on the flash drive. See Storing Pump Program Settings to the
Flash Drive, page 37 for instructions.

USB Error 07

Bad pump program settings file
USB Error 13

Unplug the flash drive and
re-install.
• Cycle power and re-install the
flash drive.
• Retry using a different flash
drive.
If any of the above do not rectify the
error, contact Graco Customer Service.

The pump programs settings file is
corrupt. Restore file to the flash drive.
See Storing Pump Program Settings
to the Flash Drive, page 37 for
instructions.
The following operations can be
attempted if another error occurs
using the USB.
•

All other USB errors

•
•

Unplug the flash drive and reinstall.
Cycle power and re-install the
flash drive.
Retry using a different flash
drive.

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

332305B

Maintenance

Maintenance
Frequency

Component

Required Maintenance

Daily and at refill

Zerk Fittings

Keep all fittings clean using a clean
dry cloth. Dirt and/or debris can damage pump and/or lubrication system.

Daily

G3 Pump Unit and Reservoir

Keep pump unit and reservoir clean
using a clean dry cloth.

Daily

Display

Keep display clean using a clean dry
cloth.

Monthly

External Wiring Harness

Verify external harnesses are secure.

332305B

Parts - 2 Liter Models

Parts - 2 Liter Models
40b
Follower Plate
Models Only

Low Level Grease Models Only

40a
44
35
42
57

27 1

23
13
14
Low Level Oil Models Only

12
3 37

67
1

21
31

66
33
34

17 3
3
30
4 2
1 Torque to 4 in. lbs (0.45 N.m)
2 Torque to 30 in. lbs (3.4 N.m)
3 Torque to 50 in. lbs (5.6 N.m)

332305B

Parts - 4 Liter and Larger Models

Parts - 4 Liter and Larger Models
Follower Plate
Models Only

40b
40a

43
44
Low Level Grease Models Only

27 1
60
16
13

62
23
14

12
18

Low Level Oil Models Only

3 37
21

17 3
4 2

30
3

1 Torque to 4 in. lbs (0.45 N.m)
2 Torque to 30 in. lbs (3.4 N.m)
3 Torque to 50 in. lbs (5.6 N.m)

332305B

Parts

Parts
Ref

Part

Description
BASE, three pump housing

Qty
1

278142 COVER, bottom, with seal

115477 SCREW, mach, torx pan hd

127079

RECT-RING, included in Kit
571042, 571069, 571179
O-RING, 258, included in Kit
124396 571042, 571044, 571045, 571069,
571179

1
2

PLATE, ricer

BEARING, ball

PADDLE, stirring, 2 Liter models
without follower plate - models
96G017, 96G019, 96G021,
96G023, 96G025,
96G030-96G032, 96G035-96G037,
96G098, 96G110, 96G125,
96G178, included in Kit 571044
PADDLE, stirring, 4 Liter models
without follower plate - models
96G088, 96G092, 96G096,
96G099, 96G103, 96G111,
96G118, 96G126, 96G141,
96G143, 96G145, 96G151,
96G153, 96G155, 96G157,
96G159, 96G160, 96G161,
96G162, 96G181, 96G183,
96G188
PADDLE, stirring, 8 Liter models
without follower plate - models
96G089, 96G093, 96G097,
96G100, 96G104, 96G112,
96G119, 96G127, 96G142,
96G144, 96G146, 96G152,
96G154, 96G156, 96G158,
96G177
PADDLE, stirring, 12 Liter models
without follower plate - models
96G105, 96G120, 96G164,
96G165

332305B

Ref

Part

Description

PADDLE, stirring, 16 Liter models
without follower plate - models
96G106, 96G121, 96G166,
96G168, 96G169, 96G185
PADDLE, stirring, 2 Liter models
16
with follower plate - models
cont
96G018, 96G020, 96G024,
96G026, 96G115, 96G132 included
in Kit 571045
PADDLE, stirring, 4Liter models
with follower plate - models
96G090, 96G094, 96G113,
96G116, 96G128, 96G133
PUMP, element, included in Kit
17
571041
SPACER, stroke adjust, included in
18 16F368
Kit 571041
21

278145 PLUG, pump, 3/4-16

PADDLE, low level, models
96G017-96G026, 96G030-96G032,
96G035-96G037, 96G088-96G090,
96G092-96G094, 96G096-96G100,
96G103-96G106, 96G110-96G113,
96G115, 96G116,
23 278136 96G118-96G121, 96G125-96G128,
96G132, 96G133,
96G141-96G146, 96G151-96G162,
96G164-96G166, 96G168,
96G169, 96G177, 96G178,
96G181, 96G183, 96G185,
96G188
SCREW, M6, models
96G017-96G021, 96G023-96G026,
96G030-96G032, 96G035-96G037,
96G088-96G090, 96G092-96G094,
96G096-96G100, 96G103-96G106,
96G110-96G113, 96G115,
27 123025 96G116, 96G118-96G121,
96G125-96G128, 96G132,
96G133, 96G141-96G146,
96G151-96G162, 96G164-96G166,
96G168, 96G169, 96G177,
96G178, 96G181, 96G183,
96G185, 96G188

Qty

1
2
2

Parts

Ref

30
‡

Part

Description

BOARD, circuit, Max, models
96G017-96G021, 96G023-96G026,
96G030-96G032, 96G035-96G037,
96G088-96G090, 96G092-96G094,
96G096, 96G097,
96G103-96G109, 96G113,
258697 96G118-96G124, 96G128,
96G141-96G146,
96G151, 96G152, 96G155,
96G156, 96G159, 196G160,
96G164, 96G166, 96G168,
96G177, 96G178, 96G181,
96G183

BOARD, circuit, Max, DMS™
models 96G098-96G100,
96G110-96G112, 96G115,
96G116, 96G125-96G127,
‡ 262463 96G132, 96G133, 96G153,
96G154,96G157, 96G158,
96G161, 96G162, 96G165,
96G169, 96G174-96G176,
96G185, 96G186, 96G188
SCREW, machine, flat head,
models 96G017-96G021,
96G023-96G026, 96G030-96G032,
96G035-96G037, 96G088-96G090,
96G092-96G094, 96G096-96G100,
96G103-96G113, 96G115,
31 119228
96G116, 96G118-96G128,
96G132, 96G133,
96G141-96G146, 96G151-96G162,
96G164-96G166, 96G168,
96G169, 96G174-96G178,
96G181, 96G183-96G186, 96G188
33 16A579 LABEL, safety

Qty

LABEL, overlay, models
96G017-96G021, 96G023-96G026,
96G030-96G032, 96G035-96G037,
96G088-96G090, 96G092-96G094,
96G096-96G100, 96G103-96G113,
96G115, 96G116,
16A073
96G118-96G128, 96G132,
96G133, 96G141-96G146,
96G151-96G162, 96G164-96G166,
96G168, 96G169,
96G174-96G178, 96G181,
96G183-96G186, 96G188

Ref

Part

Qty

WIPER, stirring, models without follower 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 571044
WIPER, stirring, models with follower plate - models 96G018,
96G020, 96G024, 96G026,
96G090, 96G094, 96G113,
96G115, 96G116, 96G128,
96G132, 96G133 included in Kit
571045

36
37

Description

LABEL, brand
123741

2
40a 24E984

40b 16G021
1

40a 24B702

40b 16G020

FITTING, Zerk, grease, not
included on models
96G107-96G109, 96G122-96G124,
96G174-96G176, 96G186, 96G188
RESERVOIR, 2 liter, grease,
96G017-96G021, 96G023-96G026,
96G030-96G032, 96G035-96G037,
96G098, 96G110, 96G115,
96G125, 96G132, 96G178,
included in Kit 571042, 571069
RESERVOIR, 2 liter, oil, 96G107,
96G122, included in Kit 571179
RESERVOIR, 4 liter, grease,
96G088, 96G090, 96G092,
96G094, 96G096, 96G099,
96G103, 96G111, 96G113,
96G116, 96G118, 96G126,
96G128, 96G133, 96G141,
96G143, 96G145, 96G151,
96G153, 96G155, 96G157,
96G159, 96G160, 96G161,
96G162, 96G181, 96G183,
included in Kit 571183
RESERVOIR, 4 liter, oil, 96G108,
96G123, 96G175, 96G188

332305B

Parts

Ref

Part

Description

RESERVOIR, 8 liter, grease,
96G089, 96G093, 96G097,
96G100, 96G104, 96G112,
96G119, 96G127, 96G142,
40a
96G144, 96G146, 96G152,
96G154, 96G156, 96G158,
96G177
RESERVOIR, 8 liter, oil, 96G109,
40b
96G124, 96G176, 96G186,
included in Kit 571182
RESERVOIR, 12 liter, 96G105,
40a
96G120, 96G164, 96G165
RESERVOIR, 16 liter, 96G106,
40a
96G121, 96G166, 96G168,
96G169, 96G185
SEAL, follower plate, 2 liter models
278139 96G018, 96G020, 96G024,
96G026, 96G115, 96G132
41
SEAL, follower plate, 4 liter models
16F472 96G090, 96G094, 96G113,
96G116, 96G128, 96G133
PLATE, follower, 2 liter models
96G018, 96G020, 96G024,
96G026, 96G115, 96G132
42
PLATE, follower, 4 liter models
96G090, 96G094, 96G113,
96G116, 96G128, 96G133
ROD, follower plate, 2 liter models
96G018, 96G020, 96G024,
96G026, 96G115, 96G132
43
ROD, follower, 4 liter models
96G090, 96G094, 96G113,
96G116, 96G128, 96G133
SPRING, compression, 2 liter models 96G018, 96G020, 96G024,
96G026, 96G115, 96G132
44
SPRING, compression, 4 liter models 96G090, 96G094, 96G113,
96G116, 96G128, 96G133
BAFFLE, low level, 2 liter models
96G017, 96G019, 96G021,
96G023, 96G025, 96G030 45† 24D838
96G032, 96G035-96G037,
96G098, 96G110, 96G125,
96G178

332305B

Qty

Ref

Part

†

24E246

†

24F836

†

24F923

†

24F924

117156

1
1
1

58 196548

Description
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
BAFFLE, low level, 8 liter models
96G089, 96G093, 96G097,
96G100, 96G104, 96G112,
96G119, 96G127, 96G142,
96G144, 96G146, 96G152,
96G154, 96G156, 96G158,
96G177
BAFFLE, low level, 12 liter models
96G105, 96G120, 96G164,
96G165
BAFFLE, low level, 16 liter models
96G106, 96G121, 96G166,
96G168, 96G169, 96G185
BEARING, sleeve, models
96G017-96G021, 96G023-96G026,
96G035-96G037, 96G088-96G090,
96G092-96G094, 96G096-96G100,
96G103-96G106, 96G110-96G113,
96G115, 96G116,
96G118-96G121, 96G125-96G128,
96G132, 96G133,
96G141-96G146, 96G151-96G157,
96G160-96G162, 96G164,
96G165, 96G177, 96G178,
96G181, 96G183, 96G185
LABEL, models 96G019, 96G020.
96G025. 96G026, 96G032,
96G037, 96G092-96G094,
96G118-96G128, 96G132,
96G133, 96G145, 96G146,
96G166, 96G174-96G176, 96G183

Qty

Parts

Ref

Part

Description

WASHER, low level, models
96G017-96G021, 96G023-96G026,
96G030-96G032, 96G035-96G037,
96G088-96G090, 96G092-96G094,
96G096-96G100, 96G103-96G106,
96G110-96G113, 96G115,
16D984 96G116, 96G118-96G121,
96G125-96G128, 96G132,
96G133, 96G141-96G146,
96G151-96G162, 96G164,
96G165-96G168, 96G177,
96G178, 96G181, 96G183,
96G185
RESERVOIR, mid-section, 8 liter
models 96G089, 96G093, 96G097,
96G100, 96G104, 96G109,
96G112, 96G119, 96G124,
96G127, 96G142, 96G144,
96G146, 96G152, 96G154,
96G156, 96G158, 96G176,
96G166. 96G177, 96G186
RESERVOIR, mid-section, 12 liter
models 96G105, 96G120, 96G164,
96G165
RESERVOIR, mid-section, 16 liter
models 96G106, 96G121, 96G166,
96G168, 96G169, 96G185
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
NUT, oil, models 96G107, 96G108,
96G109, 96G122, 96G123,
126417
96G124, 96G175, 96G176,
96G186
FLOAT, oil, models 96G107,
24N806

Qty

Ref

Part

Description

Qty

CABLE,15 ft (4.5 m), SOOW
w/7pos, 3 pin, 90 deg
CABLE, 15 ft (4.5 m), SOOW w/7
126218
pos, 5 pin, 90 deg
200 126219 CABLE, 20 ft (6.1 m), SOOW, w/7
pos, 5 pin, 90 deg
CABLE, 30 ft (9.1m) SOOW, w/7
126220
pos, 5 pin, 90 deg
126217

16U790 CABLE, DIN, bare)

1
1

CABLE, M12, 15 ft., 4 wire, straight
male to flying leads
201
CABLE, M12, 15 ft., 4 wire, straight
124333
male to female
CONNECTOR, Eurofast, fem,
124301
straight, 4Pin

202 124594
CONNECTOR, Eurofast, 4 Pin

124595 CONNECTOR, Eurofast, 5 Pin

124300

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 31, Part No. 119228 and Ref 34, Part
No. 16A073
† Also order Ref. 57, Part No. 117156 when ordering
this part.

96G108, 96G109, 96G122, 96G123,
96G124, 96G175, 96G176, 96G186,

96G188

332305B

Parts

Pressure Relief Valves

Fuses

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.

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

Description

VALVE, pressure relief, 500-3500 psi (3.44
MPa, 34.4 bar - 24.1 MPa, 241 bar), Set
16C807
pressure 3000 psi + 10% (20.68 MPa, 206.8
bar + 10%) Included in Kit 571028
VALVE, pressure relief, 750 psi (5.17 MPa,
563156
51.71 bar)
VALVE, pressure relief, 1000 psi (6.89 MPa,
563157
68.95 bar)
VALVE, pressure relief, 1500 psi (10.34 MPa,
563158
103.42 bar)
VALVE, pressure relief, 2000 psi (13.78 MPa,
563159
137.89 bar)
VALVE, pressure relief, 2500 psi (17.23 MPa,
563160
172.36 bar)
VALVE, pressure relief, 3000 psi (20.68 MPa,
563161
206.84 bar)
VALVE, pressure relief, 5500 psi (37.92 MPa,
563190
379.21 bar)

332305B

Qty
1

1
1
1
1
1
1
1

Qty

571039 FUSE, 12 volt DC

571040 FUSE, 24 volt DC

Installation and Repair Kits
Kit No.

ti15644

Description

571026 KIT, output union, 3 pump
571063 KIT, output union, 2 pump
KIT, return to reservoir NPT, includes pres571028
sure relief valve 16C807
KIT, return to reservoir BSPP, includes pres571071
sure relief valve 16C807
571030 KIT, remote manual run, 12 volt DC
571031 KIT, remote manual run, 24 volt DC
KIT, remote manual run, 12 volt DC, with
571032
cable
KIT, remote manual run, 24 volt DC with
571033
cable
571036 KIT, cover with “G” label
571041 KIT, pump element, includes Ref 17, 18, 33
KIT, repair, 2 liter reservoir, includes Ref 13,
571042
36, 40
KIT, repair, 2 liter reservoir, for models with
571069
follower plate, includes Ref 13, 36, 40
KIT, replacement, paddle, 2 liter, for models
571044 without follower plate, includes Ref 13, 16,
35, 57
KIT, replacement, paddle, 2 liter, for models
571045 with follower plate, includes Ref 13, 16,
35,40a, 42, 57
KIT, replacement, paddle, 4-16 liter, for
571046 models without follower plate, includes Ref
13, 16, 35, 57
KIT, replacement, paddle, 4 liter, for models
571047 with follower plate, includes Ref 13, 16, 35,
57
571058 KIT, output adapter, NPT
571070 KIT, output, adapter, BSPP
571060 KIT, fill, zerk, leakproof
KIT, repair, reservoir oil, 2 liter models,
571179
includes Ref 13, 36, 40b
KIT, repair, reservoir, oil 4 liter models,
571182
includes Ref 13, 36, 40b
KIT, repair, reservoir, grease, 4 liter models,
571183
includes Ref 13, 36, 40b

Manual
Number
3A0523

3A0525

3A0528

NA
3A0533
3A0534

3A0535

3A0522
NA

3A0534

Technical Data

Technical Data
A

Maximum Working Pressure
Power
100-240 VAC
12 VDC
24 VDC
Outputs - Alarm Relay
Rated Load
Max Operation Voltage
Max Operating Current
Max Switching Capacity
Min Permissible Load

Outputs - Vent Valve
Required Vent Valve Type
Output Voltage
100/240 VAC
12 VDC
24 VDC
Max Operating Current
Max Operating Power
Inputs - Cycle Pressure, 1, 2, 3, Machine Count
Required Switch Type
Sensor Voltage
100/240 VAC
12 VDC
24 VDC
Load Current
100/240 VAC
12 VDC
24 VDC
Maximum Residual Voltage
100/240 VAC
12 VDC
24 VDC
Maximum Off Current
100/240 VAC
12 VDC
24 VDC
Input Impedance
Response Time
Cycle Rate

5100 psi (35.1 MPa, 351.6 bar)
88 - 264 VAC; 0.8 A current, 90 VA Power, 47/63 Hz,
Single phase, inrush/locked rotor, max 40A (1ms)
9 - 16 VDC; 5 A current, 60 W, inrush/locked rotor 12 A
18 - 32 VDC; 2.5 A current, 60 W, inrush/locked rotor 6 A
Resistive: 0.4 A at 125 VAC, 2 A at 30 VDC
Inductive: 0.2 A at 125 VAC, 1 A at 30 VDC
Resistive: 250 VAC, 220 VAC
Inductive: 250 VAC, 220 VDC
Resistive: 3 A (AC), 3A (DC)
Inductive: 1.5 A (AC), 1.5 A (DC)
Resistive: 50 VA, 60 W
Inductive: 25 VA, 30 W
Resistive: 10 µA, 10m VDC
Inductive: 10 µA, 10m VDC
Normally closed
24 VDC
Input Voltage
Input Voltage
2A
48 W
Normally open (sink, source, or dry contact)
24 VDC
Input Voltage
Input Voltage
22mA @ 24 VDC
11mA @ 12 VDC
22mA @ 24 VDC
4V
2V
4V
1.5 mA
1 mA
1.5 mA
1.1 K
60 ms
8.0 Hz (50% duty cycle)

332305B

Technical Data

Fluid
Grease Models
Oil Models
Pumps
Pump Output

Pump Outlet
Reservoir Size
IP Rating
Sensor Inputs
Ambient Temps
Weight (Dry - includes power cord and plug)
Without follower plate
With follower plate
Wetted Parts

Sound Data

Grease NLGI 000 - #2
At least 40 cSt oil.
Up to 3
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
1/4-18 NPSF. Mates with 1/4-18 NPT male fittings
2, 4, 8, 12, 16 Liters
IP69K
3 (any of pressure or cycle)
1 (machine count)
-40°F - 158°F (-40°C to 70°C)
13.3 lbs (6.03 kg)
14.2 lbs (6.44 kg)
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
<60 dB

Dimensions
Model
2L
4L
8L
12L
16L

332305B

Height

Width

Depth

Inches

13.25
14.50
18.50
23.00
27.50

33.65
36.83
47.00
58.42
69.85

8.00
9.25
9.25
9.25
9.25

20.32
23.50
23.50
23.50
23.50

9.00
10.00
10.00
10.00
10.00

22.86
25.40
25.40
25.40
25.40

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. 37
74

332305B

Notes

332305B

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 332305

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
Modify Date                     : 2014:05:09 13:08:42-05:00
Creator Tool                    : FrameMaker 11.0
Create Date                     : 2009:12:15 10:08:57Z
Metadata Date                   : 2014:05:09 13:08:42-05:00
Format                          : application/pdf
Title                           : 332305B, G3 Max Automatic Lubrication Pump, English
Creator                         : Terri Howard
Description                     : For dispensing of NLGI Grades #000 to #2 Greases and oil with at least 40cSt.
Subject                         : 332305, 332305B, MM 332305, 332305EN, 332305EN-B, G3 Max, G3, Automatic Lubrication Pump
Job Ref                         : Z087900
Web Statement                   : G3 Max Automatic Lubrication Pump 332305
Producer                        : Acrobat Distiller 10.1.9 (Windows)
Keywords                        : 332305, 332305B, MM 332305, 332305EN, 332305EN-B, G3 Max, G3, Automatic Lubrication Pump,
Copyright                       : December 2013, revised April 2014
Marked                          : True
Document ID                     : uuid:1b8609c2-8838-4cc2-aa1d-d214986f0b5e
Instance ID                     : uuid:1ff6acae-8616-40f7-b976-f3af5c6b1f09
Page Count                      : 76
Author                          : Terri Howard

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Graco 332305B G3 Max Automatic Lubrication Pump Users Manual 332305B, Pump, English

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