Graco G3 Pro User manual

332298E
EN
Instructions
G3 Pro 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) Fill Inlet Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual. Save all instructions.
ConformstoANSI/UL73
Certified to CAN/CSA
Std. 22.2 No 68-09
3132066

Table of Contents
2332298E
Table of Contents
Part / Model Numbers . . . . . . . . . . . . . . . . . . . . . . . 3
2 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
12 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 3
16 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Understanding the Model Number . . . . . . . . . . . 4
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 8
Typical Installation - With Remote Fill Manifold . . 9
Optional Installation -
Without Remote Fill Manifold . . . . . . . . . . . 10
Choosing an Installation Location . . . . . . . . . . . 11
System Configuration and Wiring . . . . . . . . . . . 12
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Connecting to Auxiliary Fittings . . . . . . . . . . . . . 17
Setting Pump Outlet Volume . . . . . . . . . . . . . . . 18
Loading Grease . . . . . . . . . . . . . . . . . . . . . . . . 18
Auto-Fill Shut Off . . . . . . . . . . . . . . . . . . . . . . . . 20
Filling Oil Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Quick Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . 24
Pro Model Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Control Panel Overview . . . . . . . . . . . . . . . . . . 25
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Advanced Programming . . . . . . . . . . . . . . . . . . . . 29
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fault / Warning Scenarios . . . . . . . . . . . . . . . . . 33
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Parts - 2 Liter Models . . . . . . . . . . . . . . . . . . . . . . 36
Parts - 4 Liter and Larger Models . . . . . . . . . . . . . 37
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Mounting Pattern . . . . . . . . . . . . . . . . . . . . . . . . 42
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 44
Graco Information . . . . . . . . . . . . . . . . . . . . . . . 44

Part / Model Numbers
332298E 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 4. The tables below shows the relationship between each Part Number and its related Model
Number.
2 Liter Models
4 Liter Models
8 Liter Models
12 Liter Models
16 Liter Models
Part
Numbers Model Numbers
96G011 G3-G-24PR-2L0L00-R0C00000
96G012 G3-G-24PR-2LFL00-R0C00000
96G013 G3-G-ACPR-2L0L00-0D000000
96G014 G3-G-ACPR-2LFL00-0D000000
96G027 G3-G-12PR-2L0000-00C00000
96G028 G3-G-24PR-2L0000-00C00000
96G029 G3-G-ACPR-2L0000-0D000000
96G033 G3-G-12PR-2L0L05-00C00000
96G034 G3-G-24PR-2L0L05-00C00000
96G070 G3-A-24PR-2L0L00-R0C00000
96G079 G3-A-ACPR-2L0L00-0D000000
Part
Numbers Model Numbers
96G068 G3-G-24PR-4L0L00-R0C00000
96G071 G3-A-24PR-4L0L00-R0C00000
96G073 G3-G-24PR-4LFL00-R0C00000
96G075 G3-G-ACPR-4L0L00-0D000000
96G080 G3-A-ACPR-4L0L00-0D000000
96G082 G3-G-ACPR-4LFL00-0D000000
96G135 G3-G-12PR-4L0000-00C00000
96G137 G3-G-24PR-4L0000-00C00000
96G139 G3-G-ACPR-4L0000-0D000000
96G147 G3-G-12PR-4L0L05-00C00000
96G149 G3-G-24PR-4L0L05-00C00000
96G211 G3-G-24PR-4LAL05-00C00000
Part
Numbers Model Numbers
96G069 G3-G-24PR-8L0L00-R0C00000
96G072 G3-A-24PR-8L0L00-R0C00000
96G076 G3-G-ACPR-8L0L00-0D000000
96G081 G3-A-ACPR-8L0L00-0D000000
96G136 G3-G-12PR-8L0000-00C00000
96G138 G3-G-24PR-8L0000-00C00000
96G140 G3-G-ACPR-8L0000-0D000000
96G148 G3-G-12PR-8L0L05-00C00000
96G150 G3-G-24PR-8L0L05-00C00000
96G208 G3-G-ACPR-8LAL00-0D00000
96G214 G3-G-24PR-8LAL05-00C00000
Part
Numbers Model Numbers
96G077 G3-G-ACPR-120L00-0D000000
96G163 G3-G-24PR-120L05-00C00000
Part
Numbers Model Numbers
96G078 G3-G-ACPR-160L00-0D000000
96G167 G3-G-24PR-160L05-00C00000

Part / Model Numbers
4332298E
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
• PR = Pro (Timer) 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
• 05 = 5 Pin CPC power cable
• 07 = No Power Cord
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
• R = Remote Manual Run
• 0 = Not populated
G3 -G- PR 0 00 0
Code Sample: a a b b - c c d e f f - g h i j k m n p
FIG. 1
k
m
np
h
j
i
g

Warnings
332298E 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-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 offanddisconnectpoweratmainswitchbeforedisconnectinganycablesandbeforeservicing
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 voidagency 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
6332298E
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 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 eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufac-
turer
WARNING

Installation
332298E 7
Installation
Component Identification
Key:
A Reservoir
B Pump Element (1 included. Can accommodate 3 total)
C Pressure Relief Valve (Not included / required for each
outlet - Available from Graco. See Parts, page 40.)
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. 15, page 18)
G Fuse (DC models only - Not included, not shown.
Available from Graco. See Parts, page 39.)
H Control Panel
I Power / Sensor Panel (both sides; only one side shown)
J Part Number / Model Number example only shown, (see
pages 4, Understanding the Model Number, for details)
K Power Cord (DIN 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)
R Auto-Fill Shut Off
FIG. 2:
A
D
H
I
B
E
F
J
G3-G-24PR-2LFL00-R0C00000
Grease Models with Follower
Plate
L
M
96GXXX
Oil Models
N
Grease Models
R
Auto-Fill Shut Off Models

Installation
8332298E
Typical Installation
Series Progressive Divider Valve Installations
A Connected to fused power source
B Pressure relief valve (Not included/required for each outlet
- user supplied. See Parts, page 40)
C Series progressive divider valves (Divider Installations)
D To lube points
FIG. 3
A
B
C
D

Installation
332298E 9
Typical Installation - With Remote Fill Manifold
The installation shown is only a guide for selecting and installing system components. Contact your Graco distributor
for assistance in planning a system to suit your needs.
Key:
AG3Pump
B Auto-Fill Shut Off Valve
C Auto-Fill Inlet
D G3 Reservoir
E Remote Fill Reservoir
F Remote Fill Pump
G Supply Hose (user supplied)
H Air Supply to Refill Pump
J Supply Hose (user supplied)
K Pressure Relief Valve
L Drain Hose
M Fill Coupler/Inlet (quick disconnect)
N Fill Manifold
P Fill Manifold Outlet
Q Fill Manifold Vent Port
R Pressure Gauge
S Pressure Regulator and Gauge
T Pressure Relief Knob
To relieve the stall pressure in the fill line a fill manifold
(N) must be installed in the system.
FIG. 4
E
D
C
F
P
N
K
HJ
M
LA
R
Q
B
ST

Installation
10 332298E
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.
Key:
AG3Pump
B Auto-Fill Shut Off Valve
C Auto-Fill Inlet
D G3 Reservoir
E Remote Fill Reservoir
F Remote Fill Pump
HReliefValve
J Supply Hose (user supplied)
LDrainTube
L1 Option - To reservoir
L2 Option - To overflow container
S Pressure Regulator and Gauge
U Pressure Relief Valve
V Quick Disconnect
W Overflow Container
Y Supply Hose Pressure Relief Valve
To relieve the stall pressure in the fill line a ball valve
(Y) must be installed in the system.
FIG. 5
E
F
J
S
B
C
D
A
L1
HU
V
L
L2
W
Y

Installation
332298E 11
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 mounting hole layouts provided in
the Mounting Pattern section of this manual,
page 42. 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 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
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
12 332298E
System Configuration and Wiring
Grounding
If the product is permanently connected:
• It must be installed by a qualified electrician or ser-
viceman.
• It must be connected to a grounded, permanent wir-
ing system.
If an attachment plug is required in the end use
application:
• It must be rated for the product electrical specifica-
tions.
• It must be an approved, 3-wire grounding type
attachment plug.
• 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.
Fuses
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.
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 con-
nector does not exit the unit in the UP direction.
• Use a corrosion preventative electrical grease on all
contacts.
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.
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 voltage must be installed in
line with the power entry to the system.
Input Voltage Fuse Value Graco Kit No.
12 VDC 7.5 A 571039
24 VDC 4 A 571040

Installation
332298E 13
Remote Illumination Response
The following tables include graphical representations of the connector as it appears on the unit, a pin-out associated
with the connector and a typical installation wiring diagram. An internal representative wiring diagram is included
where it is deemed useful.
Wire colors provided on these pages only refer to the power cable provided by Graco with this product.
Wiring and Installation Diagrams
The following Table identifies the wiring and installation diagrams provided in this manual.
Standard Remote Illumination
(via 5 wire CPC power cable) Tri-Color Remote Illumination (M12 Connector)
Unit in OFF Mode Off Off
Unit in ON Mode On Green
Warning Condition Toggles On and Off once per second Yellow
Fault Condition Toggles On and Off once per second Red
Diagram Symbol Page #
Power DIN AC 14
Power DIN DC 14
Power CPC DC 15
Illuminated Manual Run Input Kits: 571030, 571031,
571032, 571033

Installation
14 332298E
Power DIN AC - 15 foot
Pin and Related Wire Color (FIG. 6)
Power DIN DC - 15 Foot
Pin and Related Wire Color (FIG. 7)
Pin Pin Name Color
1 Line Black
2Neutral White
3 Not Used Not Used
4Ground Green
FIG. 6
Pin Pin Name Color
1-VDC Black
2+VDC White
3 Not Used Not Used
4Not Used Green
FIG. 7

Installation
332298E 15
Power CPC DC -15 foot
Pin and Related Wire Color (FIG. 8)
Power CPC DC - 5 Wire
Part No.: 127780: 15 ft (4.5 m)
Part No.: 127781: 20 ft (6.1 m)
Part No.: 127782: 30 ft (9.1 m)
An Illuminated Remote Run Button Kit: 571030, 571031
for starting a manual run cycle if used in conjunction
with a 5-wire CPC cable, is available from Graco. Con-
tact your local Graco distributor or Graco Customer Ser-
vice for additional information about these kits.
Pin and Related Wire Color (FIG. 9)
Pin Pin Name Color
1 Not Used Not Used
2-VDC Black
3+VDC White
4 Not Used Not Used
5 Not Used Not Used
6 Not Used Not Used
7 Not Used Green
FIG. 8
Pin Pin Name Color
1 Not Used Not Used
2-VDC Black
3+VDC Red
4LIGHT White
5Manual Run
Switch Orange
6 Not Used Not Used
7 Not Used Green
FIG. 9

Installation
16 332298E
Part No. 124333: Cable Pin Out (M12)
Wire Colors (FIG. 10)
Part No. 124595: 5 Pin Eurofast Field
Wireable Connector
Part No. 124300: Field Wireable Pin Out
(M12)
Wire Colors (FIG. 12)
Part No. 124594: 4 Pin Eurofast Field
Wireable Connector
Item No. Color
1Brown
2White
3Blue
4Black
FIG. 10
FIG. 11
Item No. Color
1Brown
2White
3Blue
4Black
FIG. 12
FIG. 13

Setup
332298E 17
Setup
Pressure Relief
Follow the Pressure Relief Procedure whenever
you see this symbol.
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.
NOTE: When loosening pump element fitting, do NOT
loosen pump element. Loosening pump element will
change the output volume.
Connecting to Auxiliary Fittings
Pressure Relief Valves
NOTE: A pressure relief valve can be purchased from
Graco. See Parts, page 40.
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.
FIG. 14
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 wrenches working in opposite
directions when connecting anything to pump ele-
ment or auxiliary fittings. See FIG. 14 for an exam-
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).
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 allevi-
ate unintended pressure rises in the system and pro-
tect 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. See Technical
Data, page 37.
• Install a pressure relief valve close to every pump
outlet; before any auxiliary fitting.

Setup
18 332298E
Setting Pump Outlet Volume
NOTE:
• Before making any adjustments to pump volume,
Relieve Pressure following procedure on page 17.
• Only use Graco supplied spacers to control output
volume.
1. Use a wrench to turn pump element counter-clock-
wise to loosen. Do not remove entire pump element.
Only back pump element out enough to allow
spacer to be slid on or off.
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 (FIG. 15).
Do not use more than 2 spacers to adjust output vol-
ume.
• The amount of dispensed volume can vary depend-
ing on external conditions such as lubricant tem-
perature 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 lubrica-
tion dispense.
2. Tighten pump element fitting. Torque fitting to 50 in.
lbs (5.6 N•m).
Loading Grease
To ensure optimal performance from the G3:
• Only use NLGI #000 - #2 greases 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 (FIG. 18).
• Do not operate G3 without reservoir attached.
No. Spacers Output Volume / Minute cubic inches cubic cm
20.122
10.183
00.254
FIG. 15
NOTICE
• Always clean inlet fitting (D) (FIG. 16) with a
clean dry cloth prior to filling reservoir. Dirt
and/or debris can damage pump and/or lubrica-
tion system.
• Care must be used when filling the reservoir
using a pneumatic or electric transfer pump to
not pressurize and break the reservoir.
FIG. 16
D

Setup
332298E 19
Models without a follower plate:
1. Connect fill hose to inlet fitting (D) (FIG. 17).
2. For higher viscosity fluids, start pump to rotate stir-
ring paddle during fill to prevent air pockets from
forming in grease.
Start pump by pressing the manual run
button.
3. Fill reservoir with NLGI grease to max
fill line.
NOTE: Vent port, located in rear of reservoir, should not
be used as an overfill port/indicator.
4. Remove fill hose.
Models with a follower plate:
1. Connect fill hose to inlet fitting (D) (FIG. 17).
2. For higher viscosity fluids, start pump to rotate stir-
ring paddle during fill to prevent air pockets from
forming in grease.
Start pump by pressing the manual run
button.
3. Fill reservoir with grease until seal of
follower plate breaches the vent hole (FIG. 19) and
the majority of air is expelled from the reservoir.
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.
FIG. 17
FIG. 18
D
E
max fill line
FIG. 19
vent hole

Setup
20 332298E
Auto-Fill Shut Off
Loading Grease
To ensure optimal performance from the G3:
• Only use NLGI #000 - #2 greases appropriate for
your application, automatic dispensing, and the tem-
perature. Consult with machine and lube manufac-
turer for details.
• Do not overfill.
• Do not operate G3 without reservoir attached.
Changing Greases
When changing greases, always use compatible fluids
or greases.
The Auto-Fill Shut Off is used for refilling the G3 reser-
voir 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 pres-
surizes and brings the refilling pump to a pressurized
stall condition.
NOTE: The operator must monitor system while filling
the reservoir to prevent overfilling.
Remote Fill with Remote Fill Manifold
The reference letters used in the following instructions
refer to the Typical Installation diagram, page 9.
The fill valve is used to relieve pressure in the refill line
and to reset the Auto Fill Shut Off. See Fill Valve instruc-
tion 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 Mani-
fold (N) and Auto-Fill Shut Off Valve (B).
2. Verify the Auto-Fill Shut Off (B) pin is down, indicat-
ing it is reset (FIG. 20).
3. Remove yellow Dust Cover from Fill Coupler (M).
NOTICE
Care must be used when filling the reservoir using a
pneumatic or electric transfer pump to not pressur-
ize and break the reservoir.
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 maxi-
mum 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).
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 sys-
tem, be sure you know the maximum working pres-
sure of each component. Never exceed the
maximum working pressure of the lowest rated com-
ponent in the system. Over-pressurizing any compo-
nent 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.
FIG. 20
pin
down