Graco G3 Max Series User manual

332305G

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

2332305G

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

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Component Identification . . . . . . . . . . . . . . . . . . 9

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 10

Typical Installation -

With Remote Fill Manifold . . . . . . . . . . . . . . 11

Optional Installation -

Without Remote Fill Manifold . . . . . . . . . . . 12

System Configuration and Wiring . . . . . . . . . . . 13

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Connecting to Auxiliary Fittings . . . . . . . . . . . . . 21

Setting Pump Outlet Volume . . . . . . . . . . . . . . . 22

Loading Grease . . . . . . . . . . . . . . . . . . . . . . . . 22

Auto-Fill Shut Off . . . . . . . . . . . . . . . . . . . . . . . . 24

Filling Oil Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Quick Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . 28

Max Model Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Control Panel Overview . . . . . . . . . . . . . . . . . . 29

Programming the Max Model . . . . . . . . . . . . . . 30

Checking the Firmware Version . . . . . . . . . . . . 30

PUMP OFF / REST Setup . . . . . . . . . . . . . . . . 35

DMS™Models Only . . . . . . . . . . . . . . . . . . . . . 38

Storing Pump Program Settings

to the Flash Drive . . . . . . . . . . . . . . . . . . . . 38

Uploading Pump Program Settings

to the Pump . . . . . . . . . . . . . . . . . . . . . . . . 39

Operation / Data Log . . . . . . . . . . . . . . . . . . . . . . . 40

System Event Log . . . . . . . . . . . . . . . . . . . . . . . 40

Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Functional Summary . . . . . . . . . . . . . . . . . . . . . 43

Technical Summary . . . . . . . . . . . . . . . . . . . . . . 45

Advanced Programming . . . . . . . . . . . . . . . . . . . . 46

Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Alarms: Firmware Versions 6.01 and Below . . . . 58

Fault / Warning Scenarios . . . . . . . . . . . . . . . . . 58

Alarms: Firmware Versions 6.02 and Above . . . . 63

Fault / Warning Scenarios . . . . . . . . . . . . . . . . . 63

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Parts - 2 Liter Models . . . . . . . . . . . . . . . . . . . . . . . 72

Parts - 4 Liter and Larger Models . . . . . . . . . . . . . 73

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Mounting Pattern . . . . . . . . . . . . . . . . . . . . . . . . 79

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 80

Graco Information . . . . . . . . . . . . . . . . . . . . . . . 80

Part / Model Numbers

332305G 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. 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 4 Liter Models

Part Model Numbers

96G017 G3-G-24MX-2L0L00-10CV00R0

96G018 G3-G-24MX-2LFL00-10CV00R0

96G019 G3-G-ACMX-2L0L00-1D0V0000

96G020 G3-G-ACMX-2LFL00-1D0V0000

96G021 G3-G-12MX-2L0L00-1DMVA2R3

96G023 G3-G-24MX-2L0L00-1DMVA2R3

96G024 G3-G-24MX-2LFL00-1DMVA2R3

96G025 G3-G-ACMX-2L0L00-1DMVA2R3

96G026 G3-G-ACMX-2LFL00-1DMVA2R3

96G030 G3-G-12MX-2L0L00-10C00000

96G031 G3-G-24MX-2L0L00-10C000R0

96G032 G3-G-ACMX-2L0L00-1D000000

96G035 G3-G-12MX-2L0L05-10CV0000

96G036 G3-G-24MX-2L0L05-10CV0000

96G037 G3-G-ACMX-2L0L00-1D00A000

96G098 G3-G-12MX-2L0L00-UDMVA1R2

96G107 G3-A-24MX-2L0L00-1DMVA2R3

96G110 G3-G-24MX-2L0L00-UDMVA1R2

96G115 G3-G-24MX-2LFL00-UDMVA1R2

96G122 G3-A-ACMX-2L0L00-1DMVA2R3

96G125 G3-G-ACMX-2L0L00-UDMVA1R2

96G132 G3-G-ACMX-2LFL00-UDMVA1R2

96G174 G3-A-ACMX-2L0L00-UDMVA1R2

96G178 G3-G-24MX-2L0L00-0D00A100

96G190 G3-A-24MX-2L0L00-UDMVA1R2

96G206 G3-G-24MX-24L0L07-0D00A000

Part Model Numbers

96G088 G3-G-24MX-4L0L00-10CV00R0

96G090 G3-G-24MX-4LFL00-10CV00R0

96G092 G3-G-ACMX-4L0L00-1D0V0000

96G094 G3-G-ACMX-4LFL00-1D0V0000

96G096 G3-G-12MX-4L0L00-1DMVA2R3

96G099 G3-G-12MX-4L0L00-UDMVA1R2

96G103 G3-G-24MX-4L0L00-1DMVA2R3

96G108 G3-A-24MX-4L0L00-1DMVA2R3

96G111 G3-G-24MX-4L0L00-UDMVA1R2

96G113 G3-G-24MX-4LFL00-1DMVA2R3

96G116 G3-G-24MX-4LFL00-UDMVA1R2

96G118 G3-G-ACMX-4L0L00-1DMVA2R3

96G123 G3-A-ACMX-4L0L00-1DMVA2R3

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

96G212 G3-G-24MX-4LAL05-10CV0000

96G218 G3-G-12MX-4LFL00-10MVA2R3

Part / Model Numbers

4332305G

8 Liter Models 12 Liter Models

16 Liter Models

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

96G112 G3-G-24MX-8L0L00-UDMVA1R2

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

96G216 G3-G-24MX-8L0L08-10CV0000

96G191 G3-G-24MX-8L0L05-10CV02M3

96G195 G3-A-24MX-8L0L05-U0C0010M

96G197 G3-G-ACMX-8LFL00-1DMVA2R3

96G209 G3-G-ACMX-8LAL00-1DV00000

96G215 G3-G-24MX-8LAL05-10CV0000

96G216 G3-G-24MX-8L0L08-10CV00000

Part Model Numbers

96G105 G3-G-24MX-120L00-1DMVA2R3

96G120 G3-G-ACMX-120L00-1DMVA2R3

96G164 G3-G-24MX-120L05-10CV00000

96G165 G3-G-24MX-120L05-U0CV0100

Part 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

96G201 G3-A-ACMX-160L00-UDMVA1R2

96G219 G3-G-24MX-160L08-10CV0000

Part / Model Numbers

332305G 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.

G3 - G = Identifies pump as being a G3; G = Grease

G3 - A = Identifies pump as being a G3; A = Oil

Code aa: Power Source

• 12 = 12 Volts DC

• 24 = 24 Volts DC

• AC = 100 - 240 Volts AC

Code bb: Operation Control

• MX = Max (Cycle) Control

Code cc: Reservoir Capacity (Liters)

• 2L = 2 Liters

• 4L = 4 Liters

• 8L = 8 Liters

• 12 = 12 Liters

• 16 = 16 Liters

Code d: Follower Plate Installed

• F = Follower Plate Installed

• 0 = No Follower Plate

• A = Auto-Fill Shut Off

Code e: Low Level Option

• L = Low Level with Controller

• 0 = No Low Level monitoring

Code ff: Options

• 00 = No Options

• 03 = Powered Alarm Contact

• 05 = 5 Pin CPC power cable

•07=NoPowerCord

• 08 = Normally open vent valve with alarm,

manual run, and low level in CPC

Code g, h, i, j, k, m, n, p

NOTE: Codes g - p relate to a specific location on the

G3 pump. See FIG. 1 for these locations.

•C=CPC

•D=DIN

• 1, 2, 3 = Sensor Number

• R = Remote Manual Run

• M = Machine Count

• A = Alarm Output

•V=VentValve

• 0 = Not populated

•U=USBPort

G3 -G- MX

Code Sample: a a b b - c c d e f f - g h i j k m n p

FIG. 1

DMS™Model

Warnings

6332305G

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.

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 reg-

ulations.

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 man-

ufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and cre-

ate 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.

Warnings

332305G 7

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.

• 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 SDSs 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 equip-

ment, 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, includ-

ing eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes

but is not limited to:

• Protective eye wear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufac-

turer

WARNING

Installation

8332305G

Installation

Unpacking

The pump module was carefully packaged for shipment

by Graco. When the package arrives, perform the follow-

ing procedure to unpack the units:

1. Inspect the shipping box carefully for shipping

damage. Contact the carrier promptly if damage is

discovered.

2. Unseal the box and inspect the contents carefully.

There should not be any damaged parts.

3. Compare the packing slip against all items included

in the box. Any shortages or other inspection

problems should be reported immediately.

Choosing an Installation Loca-

tion

• Select a location that will adequately support

the weight of the G3 Pump and lubricant, as

well as all plumbing and electrical connections.

• Refer to the mounting hole layouts provided in

the Mounting Pattern section of this manual,

page 79. No other installation configuration

should be used.

• Use designated mounting holes and provided

configurations only.

• 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 fol-

lower plate, otherwise the G3 must be mounted

upright. Refer to your model number to confirm

if a follower plate was installed on your pump.

See page 5, Understanding the Model Number

to identify this character in your model number.

• Use the three fasteners (included) to secure the

G3 to the mounting surface.

• Some installations may require an additional

reservoir support bracket. See Table below for

bracket information

NOTICE

Observe precautions for handling electrostatic sensi-

tive devices. Touch ground before handling pump.

AUTOMATIC SYSTEM ACTIVATION HAZARD

If the system is equipped with has an automatic timer

(user supplied) that activates the pump lubrication

system when power is connected or when exiting the

programming function, unexpected activation of the

system could result in serious injury, including skin

injection and amputation.

Before you install or remove the lubrication pump

from the system, disconnect and isolate all power

supplies and relieve all pressure.

Part No Description

571159 Reservoir bracket and strap

125910 L-Bracket for pump

127665 USP to G-Series mounting bracket

Installation

332305G 9

Component Identification

Key:

AReservoir

B Pump Element (1 included. Can accommodate 3 total)

C Pressure Relief Valve (Not shown. Not included / required for

each outlet - Available from Graco. See Parts, page 75.)

D Zerk Inlet Fill Fitting (1 included / grease models only)

E Pump Outlet Plug (2 included)

F Volume Control Spacers (2 included. More spacers = less

output volume per stroke) (also see FIG. 20, page 22)

G Fuse (DC models only - Not included, not shown. Available

from Graco. See Parts, page 76.)

H Control Panel

I Power / Sensor Panel (both sides; only one side shown)

J Part Number / Model Number example only shown, (see

pages 5, Understanding the Model Number, for details)

K Power Cord (not shown)

L Follower Plate (grease models only / not available on all

grease models)

M Vent Hole for Follower Plate (grease models only / not

available on all grease models)

N Fill cap (oil models only)

PUSBPort(DMS

™Models only)

R Auto-Fill Shut Off

FIG. 2:

G3-G-24NC-2L0A00-L0C00000

Grease Models with Follower

Plate

96GXXX

Oil Models

Grease Models

DMSTM Models

Auto-Fill Shut Off Models

Installation

10 332305G

Typical Installation

Series Progressive Divider Valve Installations

Injector Installations

A Connected to fused power source

B Pressure relief valve (Not included/required for each outlet

- user supplied. See Parts, page 75)

C - Cycle indicator sensor cable (Divider Installations)

- Pressure switch cable (Injector Installations)

D - Series progressive divider valves (Divider Installations)

- Injectors (Injector Installations)

E To lube points

F - Proximity Switch (Divider Installations)

- Pressure switch (Injector Installations)

G Vent valve (Not included / available from Graco. See

Parts, beginning on page 74.)

H Return to reservoir

FIG. 3

FIG. 4

This manual suits for next models

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