The Part Number is a six-digit unique number that is only used to order the G3 Pump. Directly related to this six digit
Part Number is the configured Graco Model Number. This configured number identifies the distinct features of a specific G3 Pump. To help you understand each component that makes up the Model Number see Understanding Your
Model Number, page 4. The tables below shows the relationship between each Part Number and its related Model
Number.
Use the Code Sample provided below to identify each component’s location in the Model Number. The options for
each component that make up the code are provided on the lists below.
NOTE: Other pump configurations are available that are not documented in this manual. Contact Graco Customer
Service or your local Graco distributor for assistance.
Code Sample:aabb-ccdeff-ghijkm np
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
•NC = No Controller
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
G3 - G-NC0 0000 0
Code e: Low Level Option
•A = External Low Level
•0 = No Low Level monitoring
Code ff: Options
•00 = No Options
•06 = 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 F
•C = CPC
•D = DIN
•L = Low Level
•0 = Not populated
IG. 1 for these locations.
FIG. 1
4332291G
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where
applicable.
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause
electric shock.
•Turn off and disconnect power at main switch before disconnecting any cables and before servicing
or installing equipment.
•Connect only to grounded power source.
•All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
•Do not operate the unit when fatigued or under the influence of drugs or alcohol.
•Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
•Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
•Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
•Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
•Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.
•Make sure all equipment is rated and approved for the environment in which you are using it.
•Use equipment only for its intended purpose. Call your distributor for information.
•Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
•Do not kink or over bend hoses or use hoses to pull equipment.
•Keep children and animals away from work area.
•Comply with all applicable safety regulations.
332291G5
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.
•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
6332291G
Installation
A
D
H
B
E
J
F
I
G3-G-24NC-2L0A00-L0C00000
Grease Models with Follower
Plate
K
L
96GXXX
Oil Models
M
Grease Models
N
Auto-Fill Shut Off Models
Component Identification
Installation
FIG. 2
Key:
AReservoir
BAdjustable Pump Element (1 included. Can accommodate 3
total)
CPressure Relief Valve (Not included (not shown) / required for
each outlet - Available from Graco. See Parts, page 32.)
DZerk Inlet Fill Fitting (1 included / grease models only)
EPump Outlet Plug (2 included)
FVolume Control Spacers (2 included. More spacers = less
output volume per stroke) (also see F
GFuse (DC models only - Not included, not shown. Available
from Graco. See Parts, page 32.)
HPower / Sensor Panel (both sides; only one side shown)
IPart Number / Model Number example only shown, (see
JPower Cord (DIN shown)
page 4, Understanding the Model Number, for details)
KFollower Plate (grease models only / not available on all
LVent Hole for Follower Plate (grease models only / not
MFill cap (oil models only)
NAuto-Fill Shut Off
IG. 18, page 19)
grease models)
available on all grease models)
332291G7
Installation
A
B
D
E
F
C
A
B
D
E
F
H
G
C
Typical Installation
Series Progressive Divider Valve
FIG. 3
Injector Installations
FIG. 4
Key
AConnected to fused power source
BPressure relief valve (Not included/ required for each out-
let - user supplied. See Parts, page 32)
CSupply Hose (user supplied)
DSeries progressive divider valves (Divider Installations)
- Injectors (Injector Installations)
8332291G
ETo lube points
F - Proximity Switch (Divider Installations)
- Pressure switch (Injector Installations)
G Vent valve (Not included / available from Graco. See
Parts, page 33.)
H Return to reservoir
Installation
E
D
C
F
P
N
K
H
J
M
L
A
R
Q
B
S
T
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.
FIG. 5
Key:
AG3 Pump
BAuto-Fill Shut Off Valve
CAuto-Fill Inlet
DG3 Reservoir
ERemote Fill Reservoir
FRemote Fill Pump
GSupply Hose (user supplied)
HAir Supply to Refill Pump
JSupply Hose (user supplied)
KPressure Relief Valve
LDrain Hose
MFill Coupler/Inlet (quick disconnect)
NFill Manifold
PFill Manifold Outlet
QFill Manifold Vent Port
RPressure Gauge
SPressure Regulator and Gauge
TPressure Relief Knob
To relieve the stall pressure in the fill line a fill manifold
(N) must be installed in the system.
332291G9
Installation
E
F
J
S
B
C
D
A
L1
H
U
V
L
L2
W
Y
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.
FIG. 6
Key:
AG3 Pump
BAuto-Fill Shut Off Valve
CAuto-Fill Inlet
DG3 Reservoir
ERemote Fill Reservoir
FRemote Fill Pump
HRelief Valve
JSupply Hose (user supplied)
LDrain Tube
L1 Option - To reservoir
L2 Option - To overflow container
SPressure Regulator and Gauge
UPressure Relief Valve
VQuick Disconnect
W Overflow Container
YSupply Hose Pressure Relief Valve
To relieve the stall pressure in the fill line a ball valve
(Y) must be installed in the system.
10332291G
Choosing an Installation Location
AUTOMATIC SYSTEM ACTIVATION HAZARD
If the system is equipped with has an automatic timer
(user supplied) that activates the pump lubrication
system when power is connected or when exiting the
programming function, unexpected activation of the
system could result in serious injury, including skin
injection and amputation.
Before you install or remove the lubrication pump
from the system, disconnect and isolate all power
supplies and relieve all pressure.
•Select a location that will adequately support
the weight of the G3 Pump and lubricant, as
well as all plumbing and electrical connections.
•Refer to the mounting hole layouts provided in
the Mounting Pattern section of this manual,
page 35. No other installation configuration
should be used.
Installation
•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 follower plate, otherwise the G3 must be mounted
upright. Refer to your model number to confirm
if a follower plate was installed on your pump.
See page 4, Understanding the Model Number
to identify this character in your model number.
•Use the three fasteners (included) to secure the
G3 to the mounting surface.
•Some installations may require an additional
reservoir support bracket. See Table below for
bracket information
Part No Description
571159 Reservoir bracket and strap
125910 L-Bracket for pump
127665 USP to G-Series mounting bracket
332291G11
Installation
System Configuration and Wiring
Grounding
The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides an escape wire for the electric
current.
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:
•it must be rated for the product electrical specifications.
•it must be an approved, 3-wire grounding type
attachment plug.
Fuses
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.
Input Voltage
12 VDC7.5 A571039
24 VDC
Fuse Value
4 A
Graco Kit No.
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.
•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.
12332291G
Wiring and Installation Diagrams
The following Table identifies the wiring and installation
diagrams for the cable included with the pump provided
in this manual.
Diagram
Symbol
Power DIN AC13
Power DIN DC14
Power CPC DC14
Low Level Outputs15
Page
Power DIN AC - 15 foot
Pin and Related Wire Color (FIG. 7)
PinPin NameColor
1LineBlack
2Neutral White
3Not UsedNot Used
4
GroundGreen
Installation
FIG. 7
332291G13
Installation
Power DIN DC - 15 foot
Pin and Related Wire Color (FIG. 8)
PinPin NameColor
1-VDCBlack
2+VDCWhite
3Not UsedNot Used
4
Not UsedGreen
Power CPC DC - 15 foot
Pin and Related Wire Color (FIG. 9)
PinPin NameColor
1Not UsedNot Used
2-VDCBlack
3+VDCWhite
4Not UsedNot Used
5Not UsedNot Used
6Not UsedNot Used
7Not UsedGreen
FIG. 8
14332291G
FIG. 9
Installation
Power CPC DC - With Low
Level
Pin and Related Wire Color (FIG. 10)
PinPin NameColor
1Not UsedNot Used
2-VDCBlack
3+VDCRed
4LL N.O.White
5LL COMOrange
6Not UsedNot Used
7Not UsedGreen
Low Level Outputs
See Low Level Output Option, page 25 for functional
description. See Technical Data, page 34 for ratings.
Pins (F
PinPin Name
IG. 11)
1Not Used
2Not Used
3LL N.O.
4LL COM
FIG. 11
Pins (F
IG. 12)
PinPin Name
1LL N.O.
2Not Used
3LL COM
4Not Used
FIG. 10
332291G15
FIG. 12
Installation
Part No. 124333: Cable Pin Out (M12)
Part No. 124300: Field Wireable Pin Out
(M12)
Wire Colors (FIG. 13)
Item No.Color
1Brown
2White
3Blue
4Black
Wire Colors (FIG. 14)
Item No.Color
1Brown
2White
3Blue
4Black
FIG. 14
FIG. 13
16332291G
Part No. 124594: 4 Pin Eurofast Male Field
Wireable Connector (FIG. 15)
FIG. 15
Part No. 124595: 5 Pin Eurofast Male Field
Wireable Connector (FIG. 16)
Installation
FIG. 16
332291G17
Setup
Setup
Pressure Relief
Follow the Pressure Relief Procedure whenever
you see this symbol.
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 dispensing 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.
Connecting to Auxiliary Fittings
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.
•Always use two wrenches working in opposite
directions when connecting anything to pump element or auxiliary fittings. See F
ple.
•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
IG. 17 for an exam-
NOTE: When loosening pump element fitting, do NOT
loosen pump element. Loosening pump element will
change the output volume.
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.
•Only use a pressure relief valve that is rated for
no more than the working pressure of any component installed in the system. See Technical
Data, page 30.
•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 32.
FIG. 17
18332291G
Setup
Setting Pump Outlet Volume
NOTE:
•Before making any adjustments to pump volume,
Relieve Pressure following procedure on page 18.
•Only use Graco supplied spacers to control output
volume.
•It may be necessary to repeat this outlet volume
setup procedure after the pump is operating to
re-adjust the volume of dispensed fluids.
1. Use a wrench to turn pump element counter-clockwise to loosen. Do not remove entire pump element.
Only back pump element out enough to allow
spacer to be slid on or off (F
IG. 18).
3. Tighten pump element fitting. Torque fitting to 50 in.
lbs (5.6 N•m).
•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.
Loading Grease
To ensure optimal performance from the G3:
•Only use NLGI #000 - #2 greases appropriate for
your application, automatic dispensing, and the 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.
FIG. 18
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 (F
Do not use more than 2 spacers to adjust output volume.
No. Spacers
20.122
10.183
00.254
IG. 18).
Output Volume / Minute
cubic inchescubic cm
•Do not overfill.
•Do not operate G3 without reservoir attached.
NOTICE
•Always clean fitting (D) (FIG. 19) 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.
332291G19
Setup
D
vent hole
Models without a follower plate:
1. Connect fill hose to inlet fitting (FIG. 19).
FIG. 19
2. For higher viscosity fluids, start pump to rotate stirring paddle during fill to prevent air pockets from
forming in grease. Do not exceed 30 minutes run
time.
For models using an external controller, start pump
operation per your controller specifications.
Models with a follower plate:
1. Connect fill hose to inlet fitting (FIG. 19).
2. For higher viscosity fluids, start pump to rotate stirring paddle during fill to prevent air pockets from
forming in grease. Do not exceed 30 minutes run
time.
For models using an external controller, start pump
operation per your controller specifications.
3. Fill reservoir with grease until seal of follower plate
breaches the vent hole (F
air is expelled from the reservoir.
IG. 20) and the majority of
3. Fill reservoir with NLGI grease.
NOTE: Vent port, located in rear of reservoir, should not
be used as an overfill port/indicator.
4. Remove fill hose.
FIG. 20
NOTE: Vent port, located in rear of reservoir, should not
be used as an overfill port/indicator.
4. Remove fill hose.
Changing Greases
When changing greases, always use compatible fluids
or greases.
5. Turn off the air supply (H) to refill pump (F).
6. Relieve remote filling station pump pressure using
the following Remote Filling Station Pressure Relief
procedure.
20332291G
Auto-Fill Shut Off
pin
down
Setup
Loading Grease
To ensure optimal performance from the G3:
•Only use NLGI #000 - #2 greases appropriate for
your application, automatic dispensing, and the temperature. Consult with machine and lube manufacturer for details.
•Do not overfill.
•Do not operate G3 without reservoir attached.
NOTICE
Care must be used when filling the reservoir using a
pneumatic or electric transfer pump to not pressurize and break the reservoir.
Changing Greases
When changing greases, always use compatible fluids
or greases.
The Auto-Fill Shut Off is used for refilling the G3 reservoir in an automatic lubrication system. As fluid is added
to the reservoir, it pushes the plate valve up to the top of
the reservoir. The plate valve then pushes the valve pin
and closes the inlet fluid path.
When the fluid refilling path closes, the refilling line pressurizes and brings the refilling pump to a pressurized
stall condition.
NOTE: The operator must monitor system while filling
the reservoir to prevent overfilling.
COMPONENT RUPTURE HAZARD
The maximum working pressure of each component
in the system may not be the same. To reduce the
risk of over-pressurizing any component in the system, be sure you know the maximum working pressure of each component. Never exceed the
maximum working pressure of the lowest rated component in the system. Over-pressurizing any component can result in rupture, fire, explosion, property
damage and serious injury.
Regulate input pressure to the remote fill pump so
that no fluid line, component or accessory is over
pressurized.
Remote Fill with Remote Fill Manifold
The reference letters used in the following instructions
refer to the Typical Installation diagrams starting on
pages 8.
The fill valve is used to relieve pressure in the refill line
and to reset the Auto Fill Shut Off. See Fill Valve instruction manual 333393. Graco fill valve, part no. 77X542 is
available. Contact your local Graco distributor.
1. Pull out and hold the Pressure Relief Knob (T) long
enough to relieve line pressure between Fill Manifold (N) and Auto-Fill Shut Off Valve (B).
2. Verify the Auto-Fill Shut Off (B) pin is down, indicating it is reset (F
IG. 21).
The remote filling station pump stalls (dead-heads)
when the reservoir is full, causing the supply system
pressure to rise to the maximum output pressure
of the filling station pump. To help prevent equipment
damage or serious injury caused by pressurized fluid,
such as skin injection or injury from splashing fluid,
always use a remote filling station pump with a maximum output pressure of 5100 psi (35.1 MPa,
351.6 bar) and use supply hoses with a minimum
pressure rating of 5100 psi (35.1 MPa, 351.6 bar).
332291G21
FIG. 21
Setup
pin
up
pin
up
3. Remove yellow Dust Cover from Fill Coupler (M).
4. Connect Supply Hose (J) between the Remote Filling Station Pump (F) and Fill Coupler port marked
with an “I”.
5. Start Remote Filling Station Pump (F).
6. When the G3 Reservoir (D) is filled:
•the Remote Filling Station Pump (F) stalls
(dead-heads),
•the Auto-Fill Shut Off (B) pin pops up as shown
in F
IG. 22,
•the Pressure Gauge (R) rises to the fill pump’s
set pressure.
NOTE: If the pump does not stall (dead-head) there is a
leak in the system.
Remote Fill without Remote Fill Manifold
The reference letters used in the following instructions
refer to the Typical Installation diagrams starting on
pages 8.
1. A supply hose pressure relief valve (Y) and overflow
container (W) (for collecting excess fluid that drains
during pressure relief) must be installed in an easily
accessible location between the remote filling station pump (F) and the Auto-Fill Shut Off (B). This
pressure relief valve is used to relieve pressure in
the refill line and to reset the Auto-Fill Shut Off. See
Typical Installation, starting on page 9.
A Pressure Relief Kit: 247902 is available from
Graco. Contact your distributor or Graco Customer
Service for additional information about this kit.
2. Connect Supply Hose (J) at Quick Connect (V).
3. Turn on remote filling station pump (F) and fill the
G3 reservoir (D) until the indicator pin on the
Auto-Fill Valve pushes up as shown in F
pressure in the refill pump (F) builds and the pump
stalls.
IG. 23. The
FIG. 22
NO
7. Turn off the Remote Filling Station Pump (F).
8. Pull out and hold the Pressure Relief Knob (T) long
enough to relieve line pressure between Fill Manifold (N) and Auto-Fill Shut Off Valve (B) and
between Remote Filling Station Pump (F) and Fill
Manifold (N).
NOTE: The length of time it takes to vent varies depending on the system design and installation. In some
installations it may be necessary to repeat Step 8 to
ensure pressure is relieved.
9. Disconnect Supply Hose (J) at Fill Coupler (M).
10. Replace yellow Dust Cover over Fill Coupler (M).
22332291G
FIG. 23
4. Turn off the air supply (H) to pump (F).
5. Relieve remote filling station pump pressure using
the following Remote Filling Station Pressure Relief
procedure:
Setup
Y
L
W
a
b
Remote Filling Station Pressure Relief
The reference letters used in the following instructions
refer to the Typical Installation diagrams starting on
page 8.
The following Pressure Relief Procedure is only
used with the Auto-Fill Shut Off Valve to relieve
remote filling station and lubricant supply line
pressure.
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 dispensing and before
cleaning, checking, or servicing the equipment.
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 (F
•Do not operate G3 without reservoir attached.
•Only use oils with viscosity at least 40 cSt.
IG. 25).
a. To relieve pressure between the Refill Pump (F)
and Auto-Fill Shut Off (B), open ball valve (bv)
(F
IG. 24). Pressure will be released and excess
fluid will drain out of the drain tube (L) and into
the lubrication overflow container (W).
FIG. 24:
b. Close supply hose pressure relief valve (Y)
when all pressure has been relieved.
FIG. 25
1. Remove fill cap (a).
2. Pour oil into reservoir to max fill line (b).
3. Replace fill cap. Hand tighten cap, securely.
6. Disconnect the supply hose (J) from Quick Connect
(V).
332291G23
Setup
Priming
NOTE: It is not necessary to prime pump every time
pump is filled with lubricant.
Pump only requires priming the first time it is used or if it
is allowed to run dry.
1. Loosen pump element fitting (F
NOTE: When loosening pump element fitting, do NOT
loosen pump element. Loosening pump element will
change the output volume
IG. 26).
2. Only run pump until air-free lubricant is dispensed
out of element fitting (F
IG. 27).
FIG. 27
3. Tighten pump element fitting using two wrenches
working in opposite directions (F
IG. 26).
FIG. 26
24332291G
Pump Operation
200 ms
Open
Contact
Position
Closed
3 s
Pump Operation
The G3 Pump can be controlled using an external, user
supplied, power source and controller.
Refer to the Typical Installation diagrams starting on
page 8 for correct location of the required pump ground
wire and fuses.
NOTE:
•When using an external power source and controller, Pump ON (Run) Time should be set for no longer than 30 minutes.
•In most cases, Pump OFF (Rest) Time should be
twice as long as Pump ON (Run) time. If alternative
ON / OFF times are required, contact Graco Customer Service for assistance.
Low Level Output Option
Some G3 pumps without controllers include a Low Level
Output Option. It can be configured with an M12 connector in code location “G” or with a DIN connector in
code location “K”. (See Understanding the Model Number, page 4.)The low level signal is monitored across
PINS 3 and 4. For PIN 3 and 4 locations and wiring
information the Low Level Outputs diagram, page 15.
NOTE: A low level warning is triggered when the controller detects PINS 3 and 4 have momentarily closed.
Grease Pumps
When the grease level has reached a low warning level,
PINS 3 and 4 momentarily close (1 time per paddle revolution) sending the signal that the fluid has reached a
low level to the controller.
To ensure that a low level condition has been met, 3 or
more low level triggers must be detected within 1 minute
or less.
See F
IG. 28 for an illustration of a typical Low Level Out-
put response to low grease level.
Typical Low Level Output Response with Low Level Fluid in Grease Models
FIG. 28
332291G25
Pump Operation
Open
Closed
Oil Pumps
When the oil level has reached a low warning level,
PINS 3 and 4 close, sending the signal to the controller
that the fluid has reached a low level.
Typical Low Level Output Response with Low Level Fluid in Oil Models
To ensure that a low level condition has been met, the
low level trigger must be detected for 10 continuous seconds.
See F
IG. 29 for an illustration of a typical Low Level Out-
put response to low oil level.
Contact
Position
FIG. 29
26332291G
Troubleshooting
ProblemCauseSolution
Troubleshooting
Unit does not power on
Unit does not power on (DC models
only)
Unit does not power on (AC models
only)
Lubricant leaks past seal located on
the bottom of the reservoir
Unit not pumping during ON cycle,
but external controller functions
Follower plate is not going down
Pump takes several minutes before it
begins pumping at the highest pump
volume setting (no stroke adjust
spacers installed)
In an Injector System without sensor
feedback, unit does not vent properly
After wiring and installing equipment,
pump is not working
Incorrect/loose wiringRefer to Installation instructions,
page 7.
Tripped external fuse due to internal
component failure
Tripped external fuse due to pumping
non-cold weather lubricant in cold
weather -13°F (-25°C)
Tripped internal power supply fuse
due to power supply failure
Reservoir retaining tabs are cracked
or broken
Reservoir is being pressurized during
filling
Failed motorReplace unit.
Air is trapped in the reservoir
between the follower plate and lubricant
Pumping non-cold weather lubricant
in cold weather -13°F (-25°C)
Vent valve time needs to be configured
Pump wired backwardsRewire pump. See wiring and instal-
Contact Graco Customer Service.
Replace lubricant with pumpable
lubricant, rated for environmental
conditions and application.
Replace fuse.
Contact Graco Customer Service.
Replace reservoir.
Ensure vent hole is not plugged.
If problem persists, contact Graco
Customer Service or your local
Graco distributor for assistance.
Add grease following Loading
Grease instructions, page 19. Ensure
air is purged.
Add 1 stroke adjust spacer and
adjust lube cycle time to accommodate the difference in pump volume
per stroke.
Adjust external vent valve control
time.
lation diagrams, page 13
332291G27
Maintenance
Maintenance
FrequencyComponentRequired Maintenance
Daily and at refillFill FittingsKeep all fittings clean using a clean
DailyG3 Pump Unit and ReservoirKeep pump unit and reservoir clean
using a clean dry cloth.
MonthlyExternal Wiring HarnessVerify external harnesses are secure.
28332291G
Parts - 2 Liter Models
40a
44
14
1
42
13
18
17
36
33
37
41
21
15
4
3
Follower Plate Models
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. lbs (5.6 N.m)
3
2
3
40b
3
45
35
27
23
16
60
57
Low Level Grease Models
Low Level Oil Models
66
67
1
12
Parts - 2 Liter Models
332291G29
Parts - 4 Liter and Larger Models
40a
44
35
14
1
41
13
18
17
16
36
33
37
42
21
15
4
3
Follower Plate Models
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. lbs (5.6 N.m)
3
2
3
61
62
40b
3
27
1
45
60
23
57
Low Level Grease Models
67
66
Low Level Oil Models
12
Auto-Fill Shut Off Models
13
36
83
82
81
84
85
40c
87
88
74
89
45
73
72
Parts - 4 Liter and Larger Models
30332291G
Parts
Parts
RefPartDescriptionQty
1BASE, three pump housing1
3278142COVER, bottom, with seal1
4115477SCREW, mach, torx pan hd9
12127079
13124396
14PLATE, ricer1
15BEARING, ball1
16
17
1816F368
RECT-RING, included in kit
571042, 571069, 571179
O-RING, 258, included in Kit
571042, 571044, 571045, 571069,
571179
PADDLE, stirring, 2 Liter models
without follower plate, included in
Kit 571044,
PADDLE, stirring, 4 Liter or larger
models without follower plate
PADDLE, stirring, 2 Liter models
with follower plate, included in Kit
571045
PADDLE, stirring, 4 Liter and larger
models with follower plate
PUMP, element, included in Kit
571041
SPACER, stroke adjust, included in
Kit 571041
RefPartDescriptionQty
40a24B702
40b 16G020
40c17F484 RESERVOIR, 4 Liter, G3 AFSO1
1
2
1
1
1
1
1
2
278139SEAL, follower plate, 2 Liter models 1
41
16F472SEAL, follower plate, 4 Liter models 2
42PLATE, follower 1
43ROD, follower plate1
44SPRING, compression1
24D838 BAFFLE, low level, 2 Liter 1
24E246 BAFFLE, low level, 4 Liter 1
24F836BAFFLE, low level, 8 Liter 1
45†
24F923BAFFLE, low level, 12 Liter 1
24F924BAFFLE, low level, 16 Liter 1
24F836BAFFLE, low level, 8 Liter, AFSO1
57117156BEARING, sleeve1
58 196548LABEL1
RESERVOIR, 4 Liter, grease,
included in Kit 571183
RESERVOIR, 4 Liter, oil, included
in kit 571182
1
1
21278296PLUG, pump, 3/4-162
23 278136PADDLE, low level1
27123025SCREW, M61
33 16A579 LABEL, safety1
35
36LABEL, brand1
37123741
40a24E984
40b 16G021
332291G31
WIPER, stirring, models without follower plate, included in Kit 571044
WIPER, stirring, models with follower plate, included in Kit 571045
FITTING, zerk, grease, not included
on oil models
RESERVOIR, 2 Liter, grease,
included in Kit 571042, 571069
RESERVOIR, 2 Liter, oil, included
in Kit 571179
6016D984 WASHER, low level models 2
RESERVOIR, mid-section (see quantity
by size / model below)
278135
61
1
1
62278134
66NUT, oil1
6724N806 FLOAT, oil models 1
1
72PLATE, baffle, low level1
1
73SCREW, machine2
1
8 Liter models 1
12 Liter models 2
16 Liter models 3
ADAPTER, reservoir, 4 Liter models and larger
1
Parts
a
ti15644
b
a = adjustment screw
b = locking nut
RefPartDescriptionQty
74SPRING, plate, valve, reset1
81VALVE, AFSO1
82BOLT, mounting1
83PACKING, o-ring1
84PACKING, o-ring1
85SEAL, upper, reservoir1
87SEAL, lower, reservoir1
88SPACER, seal, base1
89PLATE, valve1
CABLE,15 ft (4.5 m), SOOW
127783
200
16U790
w/7pos, 3 pin, 90 deg (See Wiring
Diagram, page 14)
CABLE, DIN, to flying leads (See
Wiring Diagram, page 13)
CABLE, M12, 15 ft., 4 wire, straight
124300
201
124333
male to flying leads (See Wiring
Diagram, page 16)
CABLE, M12, 15 ft., 4 wire, straight
male to female (See Wiring Diagram, page 16)
CONNECTOR, Eurofast, fem,
straight, 4 Pin
CONNECTOR, Eurofast, 4 Pin (see
wiring diagram, page 17)
CONNECTOR, Eurofast, 5 Pin (see
wiring diagram, page 17)
202
124301
124594
124595
Replacement Danger and Warning labels, tags and
cards are available at no cost.
Also order Ref 27, Part No. 123025 and Ref 60, Part
No. 16D984
† Also order Ref. 57, Part No. 117156 when ordering
this part.
Pressure Relief Valves
Important Information regarding Pressure Relief
Valve 16C807.
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.
1
The pressure adjustment screw
1
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 bot-
1
tomed 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.
(For correct mounting configuration, choose either Option 1 or Option 2). See P/N 126916 template.
FIG. 30
332291G35
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 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.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 332291
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
www.graco.com
March 2017
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