Graco G3-G-24NC-8LTA00-0D00L000 User manual

3A6319E
EN
Instructions
G3™ One-Piece Automatic
Lubrication Pump
For dispensing of NLGI Grades #000 to #2 greases. For Professional Use Only.
Not approved for use in explosive atmospheres or hazardous (classified) locations.
Models, see page 3
5100 psi (35.1 MPa, 351.6 bar) Maximum Pump Output Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual before using this equipment. Save
these instructions.

2 3A6319E
Contents
Part / Model Numbers . . . . . . . . . . . . . . . . . . . . . . . 3
8 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 3
15 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 3
20 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Understanding the Model Number . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Component Identification . . . . . . . . . . . . . . . . . . . . 7
8 Liter Model Shown . . . . . . . . . . . . . . . . . . . . . . 7
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Series Progressive Divider Valve . . . . . . . . . . . . 8
Injector Installations . . . . . . . . . . . . . . . . . . . . . . 9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Unpack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Choose an Installation Location . . . . . . . . . . . . 10
System Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Recommendations for Pump Usage in
Harsh Environments . . . . . . . . . . . . . . . 10
Wiring and Installation Diagrams . . . . . . . . . . . 11
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure Relief Procedure . . . . . . . . . . . . . . . . 12
Connecting to Auxiliary Fittings . . . . . . . . . . . . 12
Pressure Relief Valves . . . . . . . . . . . . . . . . 12
Setting Pump Outlet Volume . . . . . . . . . . . . . . 13
Load Pump with Grease . . . . . . . . . . . . . . . . . . 13
Prime the Pump . . . . . . . . . . . . . . . . . . . . . . . . 14
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . 15
Low Level Output Option . . . . . . . . . . . . . . 15
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cleaning the Reservoir . . . . . . . . . . . . . . . . . . . 16
Recycling and Disposal . . . . . . . . . . . . . . . . . . . . . . 16
End of Product Life . . . . . . . . . . . . . . . . . . . . . . 16
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Part No./Description . . . . . . . . . . . . . . . . . . . . . . . 19
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pressure Relief Valves . . . . . . . . . . . . . . . . . . . . 20
Installation and Repair Kits . . . . . . . . . . . . . . . . 20
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Mounting Bracket Dimensions . . . . . . . . . . . . . 21
Technical Specifications . . . . . . . . . . . . . . . . . . . . 22
California Proposition 65 . . . . . . . . . . . . . . . . . . . 23
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 24
Graco Information . . . . . . . . . . . . . . . . . . . . . . . 24

Part / Model Numbers
3A6319E 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 specific G3 Pump. To help with understanding each component that makes up the Model Number, see Under-
standing the Model Number, page 4. The tables below shows the relationship between each Part Number and its
related Model Number.
8 Liter Models
12 Liter Models
15 Liter Models
20 Liter Models
Part Model Numbers
96G500 G3-G-24NC-8LTA00-0D00L000
Part Model Numbers
96G501 G3-G-24NC-12TA00-0D00L000
Part Model Numbers
96G502 G3-G-24NC-15TA00-0D00L000
Part Model Numbers
96G503 G3-G-24NC-20TA00-0D00L000

Part / Model Numbers
4 3A6319E
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 distribu-
tor 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
• 24 = 24 Volts DC
Code bb: Operation Control
• NC = No Controller
Code cc: Reservoir Capacity (Liters)
• 8L = 8 Liters
• 12 = 12 Liters
• 15 = 15 Liters
• 20 = 20 Liters
Code d: Follower Plate Installed
• T = Follower Plate Installed; Tie Rods
Code e: Low Level Option
• A = Low Level No Controller
Code ff: Options
• 00 = No Options
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.
• D = DIN
• 0 = Not populated
• L = Low Level
G 3 - G - N C
Code Sample: a a b b - c c d e f f - g h i j k m n p
FIG. 1
k
h

Warnings
3A6319E 5
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-spe-
cific hazard symbols and warnings not covered in this section may appear throughout the body of this manual
where applicable.
WARNING
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This
may look like just a cut, but it is a serious injury that can result in amputation. Get immediate
surgical treatment.
• Do not point dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking,
or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
PRESSURIZED EQUIPMENT HAZARD
Over-pressurization can result in equipment rupture.
• A pressure relief valve is required at each pump outlet.
• Follow the Pressure Relief Procedure in this manual before servicing.

Warnings
6 3A6319E
WARNING
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 Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical
Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For
complete information about your material, request Safety Data Sheets (SDSs) 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.
PLASTIC PARTS CLEANING SOLVENT HAZARD
Many cleaning solvents can degrade plastic parts and cause them to fail, which could cause serious
injury or property damage.
• Use only compatible solvents to clean plastic structural or pressure-containing parts.
• See Technical Specifications in all equipment manuals for materials of construction. Consult the
solvent manufacturer for information and recommendations about compatibility.
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.
• 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. 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.

Component Identification
3A6319E 7
Component Identification
8 Liter Model Shown
See Troubleshooting, page 17 for expanded view.
Key:
A Reservoir
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 Pressure Relief
Valves, page 20.)
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. 9, page 13)
G Fuse (DC models only - not included, not shown. Available
from Graco. See Parts, page 18.)
H Cover
J Top Mounting Bracket
K Bottom Mounting Bracket
L Part Number / Model Number example only shown, (see
pages 4, Understanding the Model Number, for details)
M Follower Plate
N Vent Port
FIG. 2
A
B
DE
F
H
J
K
L
M
N

Typical Installation
8 3A6319E
Typical Installation
Series Progressive Divider Valve
Key
A Connected to fused power source
B Pressure Relief Valve (not included; required for each
outlet - user supplied)
C Supply Hose (user supplied)
D Series Progressive Divider Valves
E To lube points
F Proximity Switch
FIG. 3
A
B
D
E
F
C

Typical Installation
3A6319E 9
Injector Installations
Key
A Connected to fused power source
B Pressure Relief Valve (not included; required for each
outlet - user supplied)
C Supply Hose (user supplied)
D Injectors
E To lube points
F Pressure Switch
G Vent Valve (not included / available from Graco. See
Parts, page 18.)
H Return to reservoir
FIG. 4
A
B
D
E
F
H
G
C

Installation
10 3A6319E
Installation
Unpack
The pump module was carefully packaged for shipment
by Graco. When the package arrives, perform the fol-
lowing 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.
Choose an Installation Location
• Select a location that adequately supports the
weight of the G3 pump and lubricant, as well as all
plumbing and electrical connections.
• Refer to the mounting hole layouts provided in
Mounting Bracket Dimensions, page 21. No other
installation configuration should be used.
• Use designated mounting holes and provided con-
figurations only.
• Use the five (5) fasteners (included) to secure the
G3 pump to the mounting surface. Three (3) fasten-
ers are used for the bottom bracket and two (2) fas-
teners are used for the top bracket.
• Adjust top mounting bracket, if necessary, to align
the bracket with the mounting surface (FIG. 5).
• Insert (user supplied) spacers if there is still a gap
after adjusting the bracket.
System Wiring
Fuses
Fuse Kits are available from Graco. The table identifies
the correct fuse to use for the input voltage and the cor-
responding Graco Kit number.
Recommendations for Pump Usage in
Harsh Environments
• If using a DIN style power or alarm harness with a
right angle mating connector, make sure the con-
nector does not exit the unit in the UP direction.
• Use a corrosion preventative electrical grease on all
contacts.
NOTICE
To prevent equipment damage, observe precautions
for handling electrostatic sensitive devices. Touch
ground before handling pump.
AUTOMATIC SYSTEM ACTIVATION HAZARD
If the system is equipped with 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 installation or removal of the lubrication pump
from the system, disconnect and isolate all power
supplies and relieve all pressure.
FIG. 5
NOTICE
Fuses (user supplied) are required on all DC mod-
els. To avoid equipment damage:
• Never operate G3 pump DC models without a
fuse installed.
• A fuse of the correct current rating must be
installed in line with the power entry to the
equipment.
Input Voltage Fuse Value Graco Kit No.
24 VDC 4 A 571040

Installation
3A6319E 11
Wiring and Installation Diagrams
The table identifies the wiring and installation diagrams
for the cable included with the pump.
Power DIN DC - 15 foot
Pin and Related Wire Color (FIG. 6)
Low Level Outputs
See Low Level Output Option, page 15 for functional
description. See Dimensions, page 21 for ratings.
Pins (FIG. 7)
Pin Pin Name Color
1 -VDC White with Blue
2 +VDC Blue
3 Not Used Not Used
4Not Used Not Used
FIG. 6
Pin Pin Name
1 LL N.O.
2 Not Used
3 LL COM
4 Not Used
FIG. 7

Setup
12 3A6319E
Setup
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
Relieve pressure in system using two (2) wrenches
working in opposite directions on the pump element
and the pump element fitting, to slowly loosen only until
fitting is loose and no more lubricant or air is leaking
from fitting.
NOTE: When loosening the pump element fitting, do
not loosen the pump element. Loosening the pump ele-
ment changes the output volume.
Connecting to Auxiliary Fittings
Pressure Relief Valves
NOTE: A pressure relief valve can be purchased from
Graco.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury
from pressurized fluid, such as skin injection, splash-
ing fluid and moving parts, follow the Pressure Relief
Procedure when you stop dispensing and before
cleaning, checking, or servicing the equipment.
FIG. 8
NOTICE
Do not attach unsupported equipment to auxiliary fit-
tings such as fill ports and pump element. Attaching
unsupported equipment to these fitting can result in
irreparable housing damage.
• Always use two (2) wrenches working in opposite
directions when connecting anything to the pump
element or auxiliary fittings. See FIG. 8 for an
example.
• Torque the pump element fittings to 50 in-lb
(5.6 N•m).
• When connecting pump element into housing,
torque to 50 in-lb (5.6 N•m).
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 alle-
viate 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 com-
ponent installed in the system.
• Install a pressure relief valve close to every
pump outlet; before any auxiliary fitting.

Setup
3A6319E 13
Setting Pump Outlet Volume
NOTE:
• Before making adjustments to the pump volume,
follow Pressure Relief Procedure, page 12.
• 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. Using a wrench, turn the pump element
counter-clockwise to loosen. Do not remove the
entire pump element, only back the pump element
out enough to allow the spacer to be added or
removed (FIG. 9).
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, one (1) spacer, or two (2) spacers (FIG. 9).
Do not use more than two (2) spacers to adjust out-
put volume.
3. Tighten the pump element fitting. Torque fitting to
50 in-lb (5.6 N•m).
• The amount of dispensed volume varies depending
upon external conditions such as lubricant tem-
perature and back pressure from downstream con-
nections.
• Use of these volume adjustments in conjunction
with setting the ON time of the pump allows for
control of the output volume.
• Use these volume adjustments as a starting point
and adjust, as necessary, to ensure desired lubrica-
tion dispense.
Load Pump with Grease
To ensure optimal performance from the G3 pump:
• Only use NLGI #000 - #2 greases appropriate for
the application, automatic dispensing, and the tem-
perature. Consult with machine and lube manufac-
turer for details.
• The reservoir can be filled using a hand operated
pump, pneumatic pump or electric transfer pump.
• Do not overfill.
• Do not operate the G3 pump without reservoir
attached.
1. Connect the fill hose to the inlet fitting.
2. For higher viscosity fluids, start pump to rotate stir-
ring paddle during fill to prevent air pockets from
forming. Do not exceed 30 minutes run time.
For models using an external controller, start pump
operation per your controller specifications.
3. For the initial run, fill the pump with grease. After all
of the air under the follower plate flows out through
the nylon line, remove the nylon line along the
transparent reservoir.
NOTE: Pull the nylon line as shown in FIG. 10 to avoid
pulling the vent port off of the pump.
FIG. 9
No. Spacers
Output Volume / Minute
cubic inches cubic cm
2 0.12 2
1 0.18 3
0 0.25 4
NOTICE
• Always clean inlet fitting with a clean dry cloth
prior to filling reservoir. Dirt and debris can
damage pump and lubrication system.
• Care must be used when filling the reservoir
using a pneumatic or electric transfer pump to
not pressurize and break the reservoir.

Setup
14 3A6319E
4. Continue filling until the follower plate reaches the
Max label, which is slightly lower than the vent port
(FIG. 10).
NOTE: The vent port, located in the rear of reservoir,
should not be used as an overfill port/indicator.
5. Remove the fill hose.
Prime the Pump
NOTE: It is not necessary to prime the pump every time
it is filled with lubricant. The pump only requires priming
the first time it is used or if it is allowed to run dry.
1. Loosen pump element fitting (FIG. 11).
NOTE: When loosening the pump element fitting, do
not loosen the pump element. Loosening the pump ele-
ment changes the output volume.
2. Only run the pump until air-free lubricant is dis-
pensed out of the element fitting (FIG. 12).
3. Tighten the pump element fitting using two (2)
wrenches working in opposite directions (FIG. 11).
FIG. 10
Vent Port
Max Label
Nylon Line
Pull Nylon Line
FIG. 11
FIG. 12

Operation
3A6319E 15
Operation
Pump Operation
The G3 pump can be controlled using an external, user
supplied, power source and controller.
Refer to Typical Installation, page 8 for correct loca-
tion of the required fuses.
NOTE:
• When using an external power source and control-
ler, Pump ON (Run) Time should be set for no lon-
ger 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 Cus-
tomer Service for assistance.
Low Level Output Option
Some G3 pumps without controllers include a Low
Level Output Option. The low level signal is monitored
across PINS 3 and 4. For PIN 3 and 4 locations and wir-
ing information see the Low Level Outputs, page 11.
NOTE: A low level warning is triggered when the con-
troller detects PINS 3 and 4 have momentarily closed.
When the grease level has reached a low warning level,
PINS 3 and 4 momentarily close (one (1) time per pad-
dle 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, three
(3) or more low level triggers must be detected within
one (1) minute or less.
See FIG. 13 for an illustration of a typical Low Level Out-
put response to low grease level.
Typical Low Level Output Response with Low Level Fluids
FIG. 13
Closed
Open
200 ms
3 s
Contact
Position

Maintenance
16 3A6319E
Maintenance
Cleaning the Reservoir
Only use water or solvents compatible with polycarbon-
ate to clean reservoir.
Recycling and Disposal
End of Product Life
At the end of the product’s useful life, dismantle and
recycle it in a responsible manner.
• Perform the Pressure Relief Procedure, page 12.
• Drain and dispose of fluids according to applicable
regulations. Refer to the material manufacturer’s
Safety Data Sheet.
• Remove motors, circuit boards, LCDs (liquid crystal
displays), and other electronic components.
Recycle according to applicable regulations.
• Do not dispose of electronic components with
household or commercial waste.
• Deliver remaining product to a recycling facility.
Frequency Component Required Maintenance
Daily and at refill Zerk Fittings Keep all fittings clean using a clean
dry cloth. Dirt and debris can dam-
age pump and lubrication system.
Daily G3 Pump Unit and Reservoir Keep pump unit and reservoir clean
using a clean dry cloth.
Monthly External Wiring Harness Verify external harnesses are secure.
NOTICE
Most solvents will degrade the polycarbonate reser-
voir and cause it to fail.

Troubleshooting
3A6319E 17
Troubleshooting
Follow the Pressure Relief Procedure, page 12 before
checking or repairing the equipment.
Problem Cause Solution
Unit does not power on Incorrect/loose wiring Refer to Installation instructions,
page 10.
Unit does not power on (DC models
only)
Tripped external fuse due to internal
component failure Contact Graco Customer Service.
Tripped external fuse due to pump-
ing non-cold weather lubricant in
cold weather -13°F (-25°C)
Replace lubricant with pumpable
lubricant, rated for environmental
conditions and application.
Replace fuse.
Lubricant leaks past seal located on
the bottom of the reservoir
Reservoir retaining tabs are cracked
or broken
Replace reservoir.
Reservoir is being pressurized during
filling
Ensure vent port is not plugged.
If problem persists, contact Graco
Customer Service or your local
Graco distributor for assistance.
Unit not pumping during ON cycle,
but controller lights and functions
Failed motor Replace unit.
Follower plate is not going down
Air is trapped in the reservoir
between the follower plate and lubri-
cant
Add grease following Load Pump
with Grease instructions, page 13.
Ensure air is purged.
Pump takes several minutes before it
begins pumping at the highest pump
volume setting (no stroke adjust
spacers installed)
Pumping non-cold weather lubricant
in cold weather -13°F (-25°C)
Add 1 stroke adjust spacer and
adjust lube cycle time to accommo-
date the difference in pump volume
per stroke.
After wiring and installing equipment
pump is not working
Pump wired backwards Rewire pump. See Wiring and
Installation Diagrams, page 11.

Parts
18 3A6319E
Parts
43
36
6
44
30
31
16
10
22
40
42
24
5
27
26
25
41
29
1
3
21
20
23
32
4
2
42
45
8 Liter Model Reservoir for 12 Liter and
Larger Models
20
21
12
10
(See 8 Liter Model for all other parts)
49

Part No./Description
3A6319E 19
Part No./Description
▲ Replacement Danger and Warning labels, tags and cards
are available at no cost.
FusesRef Part Description Qty.
1 BASE, three pump housing 1
2 SCREW< cap, hex head 4
3 RING, snap 1
4 COVER 1
5 17S695 SEAL, reservoir 1
6 BRACKET, top 1
10 RESERVOIR, 8L 1
RESERVOIR, 12L 1
RESERVOIR, 15L 1
RESERVOIR, 20L 1
12 SLEEVE (12L and larger, only) 1
16 ROD, support, 8L 4
ROD, support, 12L 4
ROD support, 15L 4
ROD, support, 20L 4
20 ROD, guide, 8L 1
ROD, guide, 12L 1
ROD, guide, 15L 1
ROD, guide, 20L 1
21 SPRING B, compression, 8L 1
SPRING A, compression, 12L 2
SPRING A, compression, 15L 2
SPRING B, compression, 20L 2
22 19B457 SEAL, grease, 16 mm id 1
23 NUT 1
24 Plate, follower 1
25 BEARING, sleeve 1
26 PLATE, wiper arm 1
27 Adapter, base, reservoir 1
29 BRACKET, bottom 1
30 COVER, vent 1
31 GASKET, vent cover 1
32 SEAL, top, foam 1
36 WASHER, flat 2
38 SPACER, pump shim (not shown) 2
39 PARTS, bracket mounting
(bagged)
1
40 SCREW, cap, hex head 2
41 NUT, jam, Ny-loc 6
42 WASHER, plain 6
43 SCREW, M8, 35 mm 2
44 NUT, M8 2
45 571041 KIT, pump element 1
46 16U790 CABLE, DIN-bare 1
47▲LABEL, safety 1
48 24M479 VALVE, vent 1
49 26D803 SEAL 1
Part Description Qty.
571040 FUSE, 24 volt DC 1

Part No./Description
20 3A6319E
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 pres-
sure relief valve as a means of
relieving pressure in day-to-day,
normal cycle operation.
The pressure adjustment screw
will require periodic adjustments.
Whenever the valve is set/adjusted (after the set point is
found) it is important to ensure that the valve is not bot-
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.
NOTE: Turning adjustment screw (a) clockwise
increases pressure.
Installation and Repair Kits
Part Description Qty
16C807◆VALVE, pressure relief, 500-3500 psi
(3.44 MPa, 34.4 bar - 24.1 MPa, 241
bar), Set pressure 3000 psi + 10%
(20.68 MPa, 206.8 bar + 10%)
Included in Kit 571028
1
563156 VALVE, pressure relief, 750 psi (5.17
MPa, 51.71 bar)
1
563157 VALVE, pressure relief, 1000 psi (6.89
MPa, 68.95 bar)
1
563158 VALVE, pressure relief, 1500 psi
(10.34 MPa, 103.42 bar)
1
563159 VALVE, pressure relief, 2000 psi
(13.78 MPa, 137.89 bar)
1
563160 VALVE, pressure relief, 2500 psi
(17.23 MPa, 172.36 bar)
1
563161 VALVE, pressure relief, 3000 psi
(20.68 MPa, 206.84 bar)
1
563190 VALVE, pressure relief, 5500 psi
(37.92 MPa, 379.21 bar)
1
a
ti15644
b
a = adjustment screw
b = locking nut
Kit No. Description
Manual
Number
571026 KIT, output union, 3 pump 3A0523
571063 KIT, output union, 2 pump
571028 KIT, return to reservoir npt,
includes pressure relief valve
16C807
3A0525
571071 KIT, return to reservoir bspp,
includes pressure relief valve
16C807
571058 KIT, output adapter, npt 3A0522
571070 KIT, output, adapter, bspp
571060 KIT, fill, zerk, leakproof NA
25E455 KIT, repair, reservoir 8 liter 3A6385
25E456 KIT, repair, reservoir, 12 liter
25E457 KIT, repair, reservoir 16 liter
25E458 KIT, repair, reservoir, 20 liter
25E485 KIT, mounting hardware NA