Instruction/ maintenance manual of the product 332305B Graco
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332305B EN Instructions G3 Max Automatic Lubrication Pump For dispensing of NLGI Gr ades #000 to #2 greases and oi l with at least 40cSt. For Professional Use Only. Not approved for use in explosive at mospheres or hazardous locations. Part Nos., page 3 5100 psi (35.
2 332305B Contents Part / Model Numbers . . . . . . . . . . . . . . . . . . . . . . . 3 2 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 8 Liter Models . . . .
Part / Model Numbers 332305B 3 Part / Model Numbers The Part Number is a six-dig it unique numb er that is on ly used to order the G3 Pump. Directly related to this six digit Part Number is the configured Gr aco Model Number. This conf igured n umber identifies the distin ct features of a spe- cific G3 Pump.
Part / Model Numbers 4 332305B 8 Liter Models 12 Liter Models 16 Liter Models Part Numbers Model Numbers 96G089 G3-G-24MX-8 L0L00-10CV00R0 96G093 G3-G-ACMX-8L0L 00-1D0V0000 96G097 G3-G- 12MX-8L0L0 0-1.
Part / Model Numbers 332305B 5 Understanding the Model Number Use the Code Sample provided below to identify each co mpon ent’s location in the Mode l Number. The options for each component that make up the code are provided on the lists below. NOTE: Some pump configur ations are not available.
Warnings 6 332305B Warnings The following warnings are fo r the setup, use, grounding, mainte nance, and repair of this equipmen t. The exclama- tion point symbol alerts you to a general wa rning and t he hazard symbol refers to procedure- specific risk.
Warnings 332305B 7 SKIN INJECTION HAZ ARD High-pressure fluid from dispensing device, hose l eaks, 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.
Installation 8 332305B Installation Grounding Component Identification Key: AR e s e r v o i r B Adjustable Pump Element (1 included. Can accommodate 3 total) C Pressure Relief Valve (Not included / required for each o utlet - Available from Graco. See Parts, page 71.
Installation 332305B 9 Typical Installation Divider Installations Injector Installations A Connected to fuse / power B Pressure relief valve (Not included/required for each outlet - user supplied.
Installation 10 332305B Choosing an Installation Location • 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 two moun ting hole layouts provid ed in the Mounting Pattern se ction of this ma nual, page 74.
Installation 332305B 11 System Configuration and Wiring If the product is permanently connected: • it must be installed by a qualified electrician or ser- viceman.
Installation 12 332305B Alarm Output and Remote Illumination Response The following tables include graphica l representations of the co nnector as it appears on the unit, a pi n-out associated with the connector and a typical insta llation wiring diagram .
Installation 332305B 13 Wiring and Installation Diagrams The following Table identi fies the wiring and inst allation diagra ms provided in this manual.
Installation 14 332305B Power DIN AC - 15 f oot: Part No. 16U790 Pin and Related Wire Color (F IG . 3) Pin Pin Name Color 1 Line Black 2 NEUTRAL White 3 Not Used Not Used 4G R O U N D G r e e n F IG .
Installation 332305B 15 Power DIN DC - 15 foot: Part No. 16U790 Pin and Related Wire Color (F IG . 4) NOTICE Be sure when power is applie d that stirring paddle rotates clockwise (when viewed from the top). If it is wired incorrectly padd le coul d rotate counter- clockwise which will damage the pump’s internal components.
Installation 16 332305B Power CPC DC -15 foot: Part No. 126217 Pin and Related Wire Color (F IG . 6) Pin Pin Name Color 1 Not Used Not Used 2- V D C B l a c k 3+ V D C W h i t e 4 Not Used Not Used 5 Not Used Not Used 6 Not Used Not Used 7 Not Used Green F IG .
Installation 332305B 17 Power CPC DC - 5 Wire 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: 571 030, 571031 for starting a manual run cycle if used in con- junction with a 5-wire CPC cable, is available from Graco.
Installation 18 332305B Inputs (M12) See Technical Data, page 72 for rat- ings. F IG . 7 1 S W + 2 N ot U se d 3 S W - 4 Signa l (3) (4) (1) (2) S in k ( N P N ) 2 or 3 w ire 1 2 3 4 S ource (P N P) 2.
Installation 332305B 19 Vent Valve Outputs See Technical Data, page 72 for ratings. F IG . 8 (1) (2) (3) 1 N ot U se d 2 Re l ief + 3 Re l ief - 1 2 3 Example Wiring Diagram P in - out Connector on Ho.
Installation 20 332305B Alarm Outputs DC example shown. See Technical Data, page 72 for ratings. F IG . 9 1 N .O. 2 N .C. 3 COM 4 N ot U se d (1) (4) (2) (3) 1 2 3 4 G3 Switch c l oses on a l arm (sho.
Installation 332305B 21 Part No. 124333: Ca ble Pin Out (M12) Wire Colors Part No. 124300: Field Wireable Pin Out (M12) Wire Colors Item No. Color 1B r o w n 2W h i t e 3B l u e 4B l a c k F IG .
Installation 22 332305B Part No. 124594: 4 Pi n Eurofast F ield Wireable Connector Part No. 124595: 5 Pi n Eurofast Field Wireable Connector F IG . 12 F IG .
Setup 332305B 23 Setup Pressure Relief Follow the Pressure Re lief Procedure whenever you see this symbol. Relieve pressure in system using two wrenches working in opposite direction s on pump element and pump element fitting to slowly loosen fitting on ly until fitting is loose and no more lubr icant or air is leaking from fitting.
Setup 24 332305B Setting Pump Outlet Volume NOTE: • Before making any ad justments to pump volume, Relieve Pressure followin g procedure on page 23. • Only use Graco supplied space rs to control output volume.
Setup 332305B 25 Models without a follower plate: 1. Connect fill hos e to inlet fitting (F IG . 16). 2. F or higher v iscosity fluids, start pump to rotate stir- ring paddle during fill to prevent air pockets from forming in grease. To start the pu mp press the m anual run button.
Setup 26 332305B Filling Oil Unit • Only use oil appropriate for you r application, auto- matic dispensing, and the equip ment’s operating temperature. Consult with mach ine and lube manu- facturer for details. • The reservoir can be fille d using a hand operated pump, pne umatic pump or electric tr ansfer pump .
Quick Setup Gui de 332305B 27 Quick Setup Guide .
Max Model Setup 28 332305B Max Model Setup Control Panel Overview (F IG . 22) NOTE: Programming instructions begin on page 29. F IG . 22 DISPLAY • A blinking LED under HH, MM, SS or ## identifies type of measurement unit you are setting; i.e., HH is hours.
Max Model Setup 332305B 29 Programming the Max Model Powering Units With Controllers By default, units with controllers are se t to operate in a timed mode with 1 minute of ON time and 8 hours of OFF time. The unit should be po wered up in O FF mode, counting down from the 8 hours.
Max Model Setup 30 332305B Setting the Real Time Clock DMS ™ Equipped Models Only NOTE: Set the real time clock prior to plugging the USB flash drive into the pump. Enter the Year: • The year displays. The first programma- ble characte r, the decade, blinks indi- cating the device is ready to program the decade digit of the year.
Max Model Setup 332305B 31 • The first programmable number of the HH (hou r) filed blinks, indicating the device is read y to program the first digit of the hour. • When programming a time of less th en 12 hours, you must program a leading zero in the first number field and press the ENTER button to save the ze ro.
Max Model Setup 32 332305B 4. The cycle field is a 2 digit number. When the correct first numeral of the number displays, press the ENTER but- ton to save the nu mber. The cursor automatically moves to the second number field. NOTE: A leading zero (0) must be entered in the first field if th e number of cycles is fewer than 10.
Max Model Setup 332305B 33 To determine the Backup Time , Graco recommends the user verify the length of time it takes to complete a typi- cal cycle and do uble that value ( to a maximum of 30 minutes). Backup Time is setup after Cy cle or Pressure Sensor Setup is complete.
Max Model Setup 34 332305B 2. Press the ENTER button to lock in the selection. The next MM number field to the right flashes indicating it is ready for programm ing. 3. Use the UP or DOWN ARROW button to scroll through numerals 0 to 9 until the desired number appea rs in the second MM number field.
Max Model Setup 332305B 35 • An LED flashes under either HH when pro- gramming ho urs OR MM when prog ram- ming minutes. • In SETUP MODE the number displa yed in the first field, on the left side of display blinks, indicating the device is ready to pro- gram the B ackup Time hours.
Max Model Setup 36 332305B 1. T o set the OF F Time us e 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 programm ing.
Max Model Setup 332305B 37 flashes and the LED lights under SS; indicating it is ready to program th e seconds fields. 5. Re peat steps 1 - 4 to se t the SS (seconds) fields. 6. After pressing the ENTER button to set the last SS field the G3 automatically switches to the RUN MODE.
Max Model Setup 38 332305B 9. G3 pump restarts cycle in the OFF mode. 10. Remove the USB flash drive. 11. After the USB flash drive is removed, pres s and hold the UP and DOWN ARROW but- tons for 3 seconds to enter the SETUP MODE (see Entering Setup Mode, pag e 29).
Operation / Data L og 332305B 39 Operation / Data Log During operation the G3 Pum p stores information as Log and Summary File s. Logs contain the following info rmation: • Log Name • DMS ID Numbe.
Operation / Data Log 40 332305B Example Event Log 2 : Pump cycle of an injector valve system with a pressure switch feedback. Common System Events are listed below. Error Log The Error Log lists Set Time and Clea r Time for the last 400 faults and warning s.
Operation / Data L og 332305B 41 Common Error Lo g entries are listed b elow. Software Fa ult An internal software erro r occurred. Contact Graco Cus- tomer Service. Low Level Warning The unit entered a low level warning mod e and is running low on material.
Operation / Data Log 42 332305B Functional Summary The Functional Summary contains two typ es of data. • The first report type, labeled User unde r the Type heading in the first column of th e Sampl.
Operation / Data L og 332305B 43 Common Functional Summa ry Data entries are listed below. Number of Cycles The number of lubrication cycles the unit has started. Total Ru n Hours Total a m ount of hours the pump has been in the ON mode of the ON/OFF cycle.
Operation / Data Log 44 332305B 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 Te chnical User Summary).
Advanced Programmi ng 332305B 45 Advanced Programming There are 7 Advanced Progra mming options. The followin g Table Id entifies each opti on and when it is used. Advanced Option Model Setting Format/ Description Why Use This? A1 Max Lockout Code (Optional) Secures setup modes with PIN Prevents unauthorize d users to adjusting settings .
Advanced Programming 46 332305B Entering a PIN Code for the First Time A1 - Setting Up PIN Code A PIN Code can be programmed into th e G3 to protect the settings from inadvertently be ing changed by unau- thorized user s. 1. Press the UP ARROW button for 10 seconds.
Advanced Programmi ng 332305B 47 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 Warn- ing and a Low Level Fault to help pro tect unit from run- ning dry. The maximum recomme nded length of time is 3:00 min- utes.
Advanced Programming 48 332305B To set Vent Valve Time: NOTE: • The LED next to the c lock in the O FF field lights and P1, P2, and P3, indi- cating the Vent Valve Time is being programmed. • Time is set as minutes and seconds ( MM:SS) only. • The small flashing LED under the MM indicates you are setting Minutes.
Advanced Programmi ng 332305B 49 3. When the correct number displays, press the ENTER button to set the num- ber. 4. Repeat 2 - 3 to set the remaining fields. 5. Press the ENTER button to exit Advanced Programming. A-5 Active Alarm Changes the alarm output behavio r.
Advanced Programming 50 332305B A-7- Constant Alar m Output on Fault This function changes the behavior of the alarm output in a fault from either t oggling once every second (default) or steady o n. Fault and Warning LEDs Illuminate 1. The default OFF is displayed.
Run Mode 332305B 51 Run Mode Time Control After setup is complete, the G3 automatically begins to run the OF F Time sequ ence (F IG . 28). • The G3 runs the progra mmed OFF sequence. (Notice the OF F Time LED on the dis play lights and the OFF Time coun ts do wn on the display.
Run Mode 52 332305B 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 pre ssure contro ls have been se t to some- thing other than OFF the display will alternate between cycles (C1, C2, C3) and/or active sensors (P1, P2, P3) and Backup Time.
Run Mode 332305B 53 Backup Time • In both Cycle and Pressure mod es 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 F IG .
Run Mode 54 332305B With machine count set, the Rest Cycle (Pump O FF) is ended when the machine co unt reaches zero (0 000). Machine Count • A set number of triggered counts. • The LED next to 1-2-3 illuminates (F IG . 34). • The display indicates the number of machine counts remaining.
Run Mode 332305B 55 Additional Controls Venting In Max models a Vent Time can be set using the Advanced Programming mo de (page 47). This is typi- cally done in a Pressure Based System ( P1) to allow injectors to reset. • Unit vents for a set amount of time (not dis- played).
Run Mode 56 332305B Manual R un Cycle To run an extra (non-programm ed) lubrica- tion cycle, push the Manual Start button. NOTE: Manual Run option is not available while unit is in Vent Mode.
Alarms 332305B 57 Alarms Any time a Fault / Warning occurs, a co mbination of LED’s will illuminate to noti fy you there is a problem and help identify the kind of Fault / Warning has occurr ed. • Faults and Warnings will not automatically clear. • To clear an fault, press and hold the RESET button on the di splay button pad for 3 seconds.
Alarms 58 332305B Low Level Fault Level of lubricant in reservoir is low and addi- tional lubricant needs to be added. Unit stops pumping and displays amount of accu- mulated time since the alarm was trigger ed. Add lubricant to rese rvoir. After lubri- cant is added press and hold the RESET button to c lear fault.
Alarms 332305B 59 Cycle / Pressure Fault In pressure mode indi- cates that unit is over pres- surized or a lubrication cycle was not completed in the user-defined amount of time. In cycle mode indicates that a cycle was not com- pleted in the user-defined amount of time.
Alarms 60 332305B System Fault An internal fault has occurred. Contact Graco Customer Service. Motor Cur- rent Warn- ing The meas ured moto r cur- rent is above the recom- mended operating maximum value. Continued use at excessive motor currents could reduce life or cause permane nt dam- age.
Alarms 332305B 61 Tempera- ture Warnin g The internal temperature of the unit is out of its recom- mended operating r ange. Use of the unit outsid e of the recommended tem- perature rang e could cause degraded system perfor- mance and possible dam- age.
Troubleshooting 62 332305B Troubleshooting Problem Cause Solution Unit does not power on Incorrect/loose wiring Refer to Installation instructions, page 8. Unit does not power on (DC models only) Tripped external fuse due to inte rnal componen t failure Contact Graco Customer Service.
Troubleshooti ng 332305B 63 In an Injector System without sensor feedback, unit does n ot vent properly Vent valve time needs to be config- ured Refer to Adva nced Programming to set ON Time, page 45. Display acts erratically Faulty cycle/pressure wiring connec- tion to unit Unplug cycle/pre ssure cables from G3.
Maintenance 64 332305B Maintenance Frequency Component Required Maintenan ce Daily and at refill Zerk Fittings Ke ep all fittings clean using a clean dry cloth. Dirt an d/or debris can dam - age pump and/or lubrication system. Daily G3 Pump Unit and Reservoir Keep pump unit and reservoi r clean using a clean dry cloth.
Parts - 2 Liter Models 332305B 65 Parts - 2 Liter Models 40a 44 14 1 42 13 18 17 34 36 33 37 41 21 30 15 4 3 31 Follower Plate Models Only 43 Torque to 4 in.
Parts - 4 Liter and Larger Models 66 332305B Parts - 4 Liter and Larger Models 40a 44 35 14 1 41 13 18 17 34 16 36 33 37 42 21 30 15 4 3 31 Follower Plate Models Only 43 Torque to 4 in. lbs (0.45 N.m) 1 Torque to 30 in. lbs (3.4 N.m) 2 Torque to 50 in.
Parts 332305B 67 Parts Ref Part Descripti on Qty 1 BASE, three pump housing 1 3 278142 COVER, bottom, with seal 1 4 115477 SCREW, mach, torx pan hd 9 12 127079 RECT-RING, included in Kit 571042, 57106.
Parts 68 332305B 30 ‡ 258697 BOARD, circuit, Max, models 96G017-96G021, 96G0 23-96G026, 96G030-96G032, 96G035-96G037 , 96G088-96G090, 96G092-96G094 , 96G096, 96G097, 96G103-96G109, 96G1 13, 96G1.
Parts 332305B 69 40a RESERVOIR, 8 lit er, grease, 96G089, 96G093, 96G097, 96G100, 96G104, 96G112, 96G119, 96G127, 96G142, 96G144, 96G146, 96G152, 96G154, 96G156, 96G158, 96G177 1 40b RESERVOIR, 8 lite.
Parts 70 332305B Replacement Danger and Warn ing labels, tags and cards are available at no cost. Also order Ref 27, Part No. 123025 an d Ref 60, Part No. 16D984 ‡ Also order Ref 31, Part No . 119228 and Ref 34, Part No. 16A073 † Also order Ref.
Parts 332305B 71 Pressure Relief Valves Important Information regar ding Pressure Relief Valve 16C807. Pressure Relief Valve 16C807 can on ly be used on the G3 Pump. It is not intended for use with any other products. The pressure relief valve uses a pressure adjustm ent scre w (a) to set the pressure release point.
Technica l Data 72 332305B Technical Data A Maximum Work ing Pressure 5100 psi (35.1 MPa , 351.6 bar) Power 100-240 VAC 88 - 264 VAC; 0.8 A current, 90 VA Power, 47/63 Hz, Single phase, inrush/locked rotor, max 40A (1ms) 12 VDC 9 - 16 VDC; 5 A current, 60 W, inrush/locked rotor 12 A 24 VDC 18 - 32 VDC; 2.
Technical Data 332305B 73 Dimensions Fluid Grease Models Grease NLGI 000 - #2 Oil Models At least 40 cSt oil. Pumps Up to 3 Pump Output 0.12 in. 3 (2 cm 3 ) / minute per outlet - 2 spacers 0.18 in. 3 (3 cm 3 ) / minute per outlet - 1 spacer 0.25 in. 3 (4 cm 3 ) / minute per outlet - 0 spacers Pump Outle t 1/4-18 NPSF.
Technica l Data 74 332305B Mounting Pattern (For correct moun ting configuration, choose either Option 1 or Op tion 2). See P/N 126916 template. F IG . 37 0.367inch 9.3 mm 2x Ø 0.366 inch 9.3 mm 3.544 inch 90.0 mm 7.0 8 7 inch 1 8 0.0 mm 1.1 8 0 inch 30.
Notes 332305B 75 Notes.
All written and visual data con tained in th is document reflects the latest product info rmation available at the time of publica tion. Graco reserves the right to make changes at any time without notice. For patent information, see www.graco.com/pate nts.
An important point after buying a device Graco 332305B (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Graco 332305B yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Graco 332305B - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Graco 332305B you will learn all the available features of the product, as well as information on its operation. The information that you get Graco 332305B will certainly help you make a decision on the purchase.
If you already are a holder of Graco 332305B, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Graco 332305B.
However, one of the most important roles played by the user manual is to help in solving problems with Graco 332305B. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Graco 332305B along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
