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Instructions
G3 Max Automatic
Lubrication Pump
For dispensing of NLGI Grades #000 to #2 greases and oil with at least 40cSt. For
Professional Use Only.
Not approved for use in explosive atmospheres or hazardous locations.
Part Nos., page 3
5100 psi (35.1 MPa, 351.6 bar) Pump Output Pressure
5000 psi (34.4 MPa, 344.7 bar) Maximum Working Pressure - Auto-Fill Shut Off
Important Safety Instructions
Read all warnings and instructions in this
manual. Save all instructions.
Conforms to ANSI/UL 73
Certified to CAN/CSA
Std. 22.2 No 68-09
3132066
332305G
EN
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Summary of Contents for Graco G3 Max Series
- Page 1 Instructions G3 Max Automatic Lubrication Pump 332305G For dispensing of NLGI Grades #000 to #2 greases and oil with at least 40cSt. For Professional Use Only. Not approved for use in explosive atmospheres or hazardous locations. Part Nos., page 3 5100 psi (35.1 MPa, 351.6 bar) Pump Output Pressure 5000 psi (34.4 MPa, 344.7 bar) Maximum Working Pressure - Auto-Fill Shut Off Important Safety Instructions...
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Page 2: Table Of Contents
Component Identification ....9 Graco Information ..... . . 80 Typical Installation . -
Page 3: 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 spe- cific G3 Pump. -
Page 4: Liter Models
Part / Model Numbers 8 Liter Models 12 Liter Models Part Model Numbers Part Model Numbers 96G105 G3-G-24MX-120L00-1DMVA2R3 96G089 G3-G-24MX-8L0L00-10CV00R0 96G120 G3-G-ACMX-120L00-1DMVA2R3 96G093 G3-G-ACMX-8L0L00-1D0V0000 96G164 G3-G-24MX-120L05-10CV00000 96G097 G3-G-12MX-8L0L00-1DMVA2R3 96G165 G3-G-24MX-120L05-U0CV0100 96G100 G3-G-12MX-8L0L00-UDMVA1R2 96G104 G3-G-24MX-8L0L00-1DMVA2R3 16 Liter Models 96G109 G3-A-24MX-8L0L00-1DMVA2R3 96G112 G3-G-24MX-8L0L00-UDMVA1R2 Part Model Numbers... -
Page 5: 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. -
Page 6: Warnings
Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama- tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable. - Page 7 Warnings WARNING SKIN INJECTION HAZARD High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgi- cal treatment. •...
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Page 8: Installation
The pump module was carefully packaged for shipment upright. Refer to your model number to confirm by Graco. When the package arrives, perform the follow- if a follower plate was installed on your pump. ing procedure to unpack the units: See page 5, Understanding the Model Number 1. -
Page 9: Component Identification
Pressure Relief Valve (Not shown. Not included / required for Vent Hole for Follower Plate (grease models only / not each outlet - Available from Graco. See Parts, page 75.) available on all grease models) Zerk Inlet Fill Fitting (1 included / grease models only) Fill cap (oil models only) ™... -
Page 10: Typical Installation
Pressure relief valve (Not included/required for each outlet - Pressure switch (Injector Installations) - user supplied. See Parts, page 75) Vent valve (Not included / available from Graco. See - Cycle indicator sensor cable (Divider Installations) Parts, beginning on page 74.) -
Page 11: Typical Installation - With Remote Fill Manifold
Installation Typical Installation - With Remote Fill Manifold The installation shown is only a guide for selecting and installing system components. Contact your Graco distributor for assistance in planning a system to suit your needs. Key: G3 Pump Auto-Fill Shut Off Valve... -
Page 12: Optional Installation - Without Remote Fill Manifold
Installation Optional Installation - Without Remote Fill Manifold The installation shown is only a guide for selecting and installing system components. Contact your Graco distributor for assistance in planning a system to suit your needs. NOTE: The remote filling station pump stalls (dead-heads) when the reservoir is full. If the pump does not stall (dead-head) there is a leak in the system. -
Page 13: System Configuration And Wiring
Grounding provides an escape wire for the electric line with the power entry to the system. current. Fuse Kits are available from Graco. The following Table identifies the correct fuse to use for your input voltage Improper installation of the grounding conductor may and the corresponding Graco Kit number. - Page 14 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...
- Page 15 Installation Alarm Relay Response Output Tied to Common N.O. No Faults or Warnings N.C. N.O. Fault (Advanced N.C. Programming A7 OFF) 1 second Fault N.O. (Advanced Programming N.C. Setting A7 ON) Wiring and Installation Diagrams The following Table identifies the wiring and installation diagrams provided in this manual. Diagram Symbol Page #...
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Page 16: Power Din Ac
Installation Power DIN AC - 15 foot: Part No. Power DIN DC - 15 foot 16U790 Pin and Related Wire Color (F . 8) Pin Name Color Pin and Related Wire Color (F . 7) -VDC Black +VDC White Pin Name Color Not Used Not Used... - Page 17 An Illuminated Remote Run Button Kit: 571030, 571031 +VDC White for starting a manual run cycle if used in conjunction with a 5-wire CPC cable, is available from Graco. Con- Not Used Not Used tact your local Graco distributor or Graco Customer Ser-...
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Page 18: Inputs (M12)
Installation Pin and Related Wire Color (F . 11) Wiring for “08” Option Inputs (M12) See Technical Data, page 77 for ratings. CPC Pin Pin Name Wire Color Not Used Not Used Connector on Housing Pin-out -VDC/Com Black +VDC Alarm White 1 SW + Manual... -
Page 19: Vent Valve Outputs
Installation Vent Valve Outputs Alarm Outputs See Technical Data, page 77 for ratings. DC example shown. See Technical Data, page 77 for ratings. . 13 . 14 332305G... - Page 20 Installation Part No. 124333: Cable Pin Out (M12) Part No. 124300: Field Wireable Pin Out (M12) Wire Colors (F . 15) Wire Colors (F . 17) Item No. Color Item No. Color Brown Brown White White Blue Blue Black Black .
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Page 21: Setup
See Technical Data, page 73. • 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 75. . 19 332305G... -
Page 22: Setting Pump Outlet Volume
Before making any adjustments to pump volume, Relieve Pressure following procedure on page 21. • Only use Graco supplied spacers to control output volume. 1. Use a wrench to turn pump element counter-clock- wise to loosen. Do not remove entire pump element. - Page 23 Setup Models without a follower plate: Models with a follower plate: 1. Connect fill hose to inlet fitting (D) (F . 22). 1. Connect fill hose to inlet fitting (D) (F . 22). 2. For higher viscosity fluids, start pump to rotate stir- ring paddle during fill to prevent air pockets from forming in grease.
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Page 24: Auto-Fill Shut Off
Auto Fill Shut Off. See Fill Valve instruc- to the reservoir, it pushes the plate valve up to the top of tion manual 333393. Graco fill valve, part no. 77X542 is the reservoir. The plate valve then pushes the valve pin available. - Page 25 A Pressure Relief Kit: 247902 is available from NOTE: If the pump does not stall (dead-head) there is a Graco. Contact your distributor or Graco Customer leak in the system. Service for additional information about this kit. 2. Connect Supply Hose (J) at Quick Connect (V).
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Page 26: Filling Oil Unit
Setup Filling Oil Unit Remote Filling Station Pressure Relief The reference letters used in the following instructions • Only use oil appropriate for your application, auto- refer to the Typical Installation diagrams starting on matic dispensing, and the equipment’s operating page 10. -
Page 27: Priming
Setup Priming 2. Only run pump until air is no longer dispensed with the lubricant coming out of element fitting (F . 31). NOTE: It is not necessary to prime pump every time pump is filled with lubricant. Pump only requires priming the first time it is used or if it is allowed to run dry. -
Page 28: Quick Setup Guide
Quick Setup Guide Quick Setup Guide 0D[ 0RGHO 6\VWHP ,QMHFWRU 6\VWHP ZLWK 6LQJOH 6HQVRU ,QSXW 6HOHFW (QWHU (QWHU 6HWXS 21%DFNXS 7LPH 00 66 (QWHU 6\VWHP 3UHOXEH 5XQV 2SWLRQ 7LPH $FFRUGLQJ ++ 00 WR 6HWWLQJV (QWHU 3UHOXEH 'HOD\ 00 66 0D[ 0RGHO 6\VWHP 'LYLGHU 9DOYH 6\VWHP ZLWK 6LQJOH 6HQVRU ,QSXW 6HOHFW 3UR[ VHQVRU (QWHU... -
Page 29: Max Model Setup
Max Model Setup Max Model Setup Control Panel Overview (F . 32) NOTE: Programming instructions begin on page 30. OFF TIME/BACKUP TIME ON TIME/BACKUP TIME • LED lights when OFF DISPLAY • LED lights when ON Time/Backup Time is used to con- •... -
Page 30: Programming The Max Model
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. - Page 31 Max Model Setup 3. The cursor is automatically 3. Use the UP and DOWN arrow but- positioned to enter the first tons to move up and down through character of the PIN Code. the number 0-9 until the number Use the UP and DOWN for the current year is displayed in ARROW buttons to move up the field.
- Page 32 Max Model Setup 3. Use the UP and DOWN ARROW buttons to move up and down 7. After pressing the ENTER button to through the numbers 0-9 until the set the time, the programmed Time second digit of the date is dis- information is saved.
- Page 33 Max Model Setup 2. When C1 is Pressure Control (P1, P2, P3) Setup on display, • For injector systems, monitoring pressure can be press the used as a way to ensure sufficient pressure has ENTER been reached to activate injectors. The pump runs, button to building up enough pressure to cause injectors to save selec-...
- Page 34 LED lights under SS; indicating it is ready to program the seconds fields. To determine the Backup Time, Graco recommends the user verify the length of time it takes to complete a typi- 5. Repeat steps 1 - 4 to set the SS (seconds) fields.
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Page 35: Pump Off / Rest Setup
• Machine Count activations limited by a maxi- If this time does not meet the application needs, mum Time, or contact Graco Customer Support. • A specific set amount of Time (similar to Time Mode). Programming ON Time •... - Page 36 • 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 pro- Programming Backup Time gramming hours OR...
- Page 37 Setting Prelube If this time does not meet the application needs, 1. After you set the OFF Time information and press contact Graco Customer Support. the ENTER button, the G3 automatically switches to the Prelube Delay setup. Programming OFF Time...
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Page 38: Dms ™ Models Only
59:59 (59 minutes:59 seconds). The pump program settings file is named: 2. Press the ENTER button to lock in the GRACO/G3Config/g3config.bin. This file cannot be selection. The next MM number field to modified. Modification of the file or file name may cause the right flashes indicating it is ready for it to be unusable. -
Page 39: Uploading Pump Program Settings To The Pump
DMS ID is displayed. • The USB flash drive must contain file GRACO/G3Config/g3config.bin. 3. Release the DOWN ARROW button after viewing the DMS ID number. • The G3 pump stops pumping as soon as the USB flash drive is plugged into it. -
Page 40: Operation / Data Log
DMS ID Number: 0025 (see page 39) • Log Name Software Part Number: 16F821 Software Version: 1019 • DMS ID Number 09/29/2010 14:1400 • Current Software Graco Part Number • Current Software Version Date Time Description • Date and Time of Upload 9/29/2010...
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