Graco G3 Pro User manual

332298M
EN
Instructions
G3® Pro Automatic
Lubrication Pump
For dispensing 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 classified 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.
Conforms to ANSI/UL 73
Certified to CAN/CSA
C22.2 No 68
3132066
100-240VAC Pumps ONLY

Table of Contents
2 332298M
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . 9
Typical Installation - With Remote
Fill Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 10
Optional Installation - Without Remote
Fill Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 11
Choosing an Installation Location . . . . . . . . . . . 12
System Configuration and Wiring . . . . . . . . . . . 13
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pressure Relief. . . . . . . . . . . . . . . . . . . . . . . . . . 17
Connecting to Auxiliary Fittings. . . . . . . . . . . . . 17
Setting Pump Outlet Volume . . . . . . . . . . . . . . . 18
Fill Reservoir - Grease Dispense Pumps . . . . . . 18
Auto-Fill Shut Off . . . . . . . . . . . . . . . . . . . . . . . . 21
Fill Reservoir - Oil Dispense Pumps . . . . . . . . . 23
Prime the Pump. . . . . . . . . . . . . . . . . . . . . . . . . 24
Quick Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . . 25
Pro Model Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Control Panel Overview (FIG. 24) . . . . . . . . . . . . 26
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Advanced Programming . . . . . . . . . . . . . . . . . . . . 31
Models with Firmware 5.01 and later . . . . . . . . 34
Models with Firmware 5.04 and later. . . . . . . . . 35
Models with Firmware 5.06 and later. . . . . . . . . 36
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Alarms: Firmware Versions 5.01 and Above . . . . 39
Fault / Warning Scenarios . . . . . . . . . . . . . . . . . 39
Fault/Warning Scenarios for Firmware Versions
5.06 and Later . . . . . . . . . . . . . . . . . . . . . . . 41
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Parts - 2 Liter Models . . . . . . . . . . . . . . . . . . . . . . . 44
Parts - 4 Liter and Larger Models . . . . . . . . . . . . . 45
Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Mount Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Technical Specifications . . . . . . . . . . . . . . . . . . . . 50
California Proposition 65 . . . . . . . . . . . . . . . . . . . . 51
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 52

Part / Model Numbers
332298M 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 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 Number
96G011 G3-G-24PR-2L0L00-R0C00000
96G012 G3-G-24PR-2LFL00-R0C00000
96G013 G3-G-ACPR-2L0L00-0D000000 X
96G014 G3-G-ACPR-2LFL00-0D000000 X
96G027 G3-G-12PR-2L0000-00C00000
96G028 G3-G-24PR-2L0000-00C00000
96G029 G3-G-ACPR-2L0000-0D000000 X
96G033 G3-G-12PR-2L0L05-00C00000
96G034 G3-G-24PR-2L0L05-00C00000
96G070 G3-A-24PR-2L0L00-R0C00000
96G079 G3-A-ACPR-2L0L00-0D000000 X
96G255 G3-G-12PR-2L0L07-00C00000
96G285 G3-G-24PR-2L0007-0D000000
96G326 G3-G-24PR-2L0007-00C00000
Part
Numbers Model Number
96G068 G3-G-24PR-4L0L00-R0C00000
96G071 G3-A-24PR-4L0L00-R0C00000
96G073 G3-G-24PR-4LFL00-R0C00000
96G075 G3-G-ACPR-4L0L00-0D000000 X
96G080 G3-A-ACPR-4L0L00-0D000000 X
96G082 G3-G-ACPR-4LFL00-0D000000 X
96G135 G3-G-12PR-4L0000-00C00000
96G137 G3-G-24PR-4L0000-00C00000
96G139 G3-G-ACPR-4L0000-0D000000 X
96G147 G3-G-12PR-4L0L05-00C00000
96G149 G3-G-24PR-4L0L05-00C00000
96G211 G3-G-24PR-4LAL05-00C00000
96G256 G3-G-24PR-4L0L07-00C00000
Part
Numbers Model Number
96G069 G3-G-24PR-8L0L00-R0C00000
96G072 G3-A-24PR-8L0L00-R0C00000
96G076 G3-G-ACPR-8L0L00-0D000000 X
96G081 G3-A-ACPR-8L0L00-0D000000 X
96G136 G3-G-12PR-8L0000-00C00000
96G138 G3-G-24PR-8L0000-00C00000
96G140 G3-G-ACPR-8L0000-0D000000 X
96G148 G3-G-12PR-8L0L05-00C00000
96G150 G3-G-24PR-8L0L05-00C00000
96G208 G3-G-ACPR-8LAL00-0D00000 X
96G214 G3-G-24PR-8LAL05-00C00000
96G257 G3-G-24PR-8L0L07-00C00000
96G268 G3-G-24PR-8LLL05-00C00000
96G270 G3-G-24PR-8LFL07-00C00000
Part
Numbers Model Number
96G077 G3-G-ACPR-120L00-0D000000 X
96G163 G3-G-24PR-120L05-00C00000
96G247 G3-G-24PR-120L00-R0C00000
Part
Numbers Model Number
96G078 G3-G-ACPR-160L00-0D000000 X
96G167 G3-G-24PR-160L05-00C00000
96G323 G3-G-24PR-160L07-00C00000

Part / Model Numbers
4 332298M
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.
Code a: Pump Fluid Type
• G = Grease
• A = Oil
Code bb: Power Source
• 12 = 12 Volts DC
• 24 = 24 Volts DC
• AC = 100 - 240 Volts AC
Code cc: Operation Control
• PR = Pro (Timer) Controller
Code dd: Reservoir Capacity (Liters)
• 2L = 2 Liters
• 4L = 4 Liters
• 8L = 8 Liters
• 12 = 12 Liters
• 16 = 16 Liters
Code e: Reservoir Feature
• F = Follower Plate Installed
• 0 = No Follower Plate
• A = Auto-Fill Shut Off
• L = Top Fill
Code f: Low Level Option
• L = Low Level with Controller
• 0 = No Low Level monitoring
Code gg: Options
• 00 = No Options
• 05 = 5 Pin CPC power cable
• 07 = No Power Cord
Code h, i, j, k, m, n, p, q
NOTE: Codes h - q 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
G 3 - - P R 0 0 0 0 0 0
Code Sample: a b b c c - d d e f g g - h i j k m n p q
FIG. 1
m
n
pq
i
k
j
h

Warnings
332298M 5
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 cord before servicing equipment.
• Connect only to grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on power and extension cords.
• 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
Specifications 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.

Warnings
6 332298M
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 and serious injury.
• A pressure relief valve is required at each pump outlet.
• Follow the Pressure Relief Procedure in this manual before servicing.
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.
WARNING

Warnings
332298M 7
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.
WARNING

Installation
8 332298M
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 47.)
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. 11, page 18)
G Fuse (DC models only - Not included, not shown.
Available from Graco. See Parts, page 47.)
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 (Not shown)
L Follower Plate (grease models only / not available on all
grease models)
M Vent Hole for Follower Plate (grease models only / not
available on all grease models)
N Fill cap (oil models only)
O Top Fill Lid
R Auto-Fill Shut Off
FIG. 2:
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
A
N
Top Fill Models
O

Installation
332298M 9
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 48)
C Series progressive divider valves (Divider Installations)
D To lube points
FIG. 3
A
B
C
D

Installation
10 332298M
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:
A G3 Pump
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
L
A
R
Q
B
S
T

Installation
332298M 11
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:
A G3 Pump
B Auto-Fill Shut Off Valve
C Auto-Fill Inlet
D G3 Reservoir
E Remote Fill Reservoir
F Remote Fill Pump
H Relief Valve
J Supply Hose (user supplied)
L Drain Tube
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
12 332298M
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 49.
No other installation configuration should be used.
• Use designated mounting holes and provided
configurations only.
• Always mount the G3 oil models upright.
• Mount top fill G3 pump so that there is a minimum
clearance of four inches (4.0 in.) (10.2 cm) above
the reservoir to allow for lid removal and filling.
• 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.
• In high vibration environments, additional isolation
at mounting point is necessary. See table below.
• AC pumps are not recommended when high
vibration or shock is present.
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
132187 Isolator mounting kit

Installation
332298M 13
System Configuration and Wiring
Grounding
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.
• 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 the 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
connector 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
models. To avoid equipment damage:
• Never operate G3 Pump DC models without a
fuse installed.
• A fuse of the correct current must be installed
in line with the power entry to the equipment.
Input Voltage Fuse Value Graco Kit No.
12 VDC 7.5 A 571039
24 VDC 4 A 571040

Installation
14 332298M
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 15
Power DIN DC 15
Power CPC DC 16
Illuminated Manual Run Input Kits: 571030, 571031,
571032, 571033

Installation
332298M 15
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
2 Neutral 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
16 332298M
Power CPC DC - 2 Wire
Part No.: 127783: 15 ft. (4.5 m)
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.
Contact your local Graco distributor or Graco Customer
Service 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
4 LIGHT White
5Manual Run
Switch Orange
6 Not Used Not Used
7 Not Used Green
FIG. 9

Setup
332298M 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 47.
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. 10
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 FIG. 10 for an
example.
• 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
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 45.
• Install a pressure relief valve close to every
pump outlet; before any auxiliary fitting.

Setup
18 332298M
Setting Pump Outlet Volume
NOTE:
• Before making any adjustments to pump volume,
follow Pressure Relief on page 17.
• Only use Graco supplied spacers to control output
volume.
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.
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 (FIG. 11).
Do not use more than 2 spacers to adjust output
volume.
NOTE:
• 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.
• Tighten pump element fitting. Torque fitting to 50
in. lbs (5.6 N•m).
Fill Reservoir - Grease Dispense
Pumps
To ensure optimal performance from the G3:
• Only use NLGI #000 - #2 greases appropriate for
the 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. 14).
• Do not operate G3 without reservoir attached.
No. Spacers Output Volume / Minute
cubic inches cubic cm
2 0.12 2
1 0.18 3
0 0.25 4
FIG. 11
• Always clean inlet fitting (D) (FIG. 12) 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.

Setup
332298M 19
Models Without a Follower Plate
1. Connect fill hose to Zerk inlet fitting (D) (FIG. 13).
2. For higher viscosity fluids, start pump to rotate
stirring 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 Top Fill
1. Disconnect the power from the equipment.
NOTE: If battery disconnect is not available, remove the
power cord (FIG. 15).
FIG. 12
FIG. 13
D
D
E
FIG. 14
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 lid removed.
•Disconnect power before removing lid.
FIG. 15
max fill line

Setup
20 332298M
2. Clean the top of the lid and the area around the top
of the reservoir to ensure that no debris falls into
the reservoir when the lid is removed.
3. Turn the lid counterclockwise to remove.
4. Place the lid in a clean area to avoid debris getting
into the inside of the lid or threads.
5. Fill the reservoir with new clean grease.
6. Make sure that no contaminants enter the reservoir.
7. Clean the threads on the reservoir and the lid.
8. Replace the lid onto the reservoir, turning clockwise
(approximately 1 3/4 turns).
9. Reconnect the power to the equipment.
Models With a Follower Plate
1. Connect fill hose to Zerk inlet fitting (D) (FIG. 13).
2. For higher viscosity fluids, start pump to rotate
stirring 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. 16) 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.
Change Greases
When changing greases, always use compatible fluids
or greases.
NOTICE
Any debris or dirt accidentally introduced into the
reservoir should be removed immediately. Do not
allow the pump to operate until any debris or dirt are
removed.
Operating the pump with debris or dirt in the reservoir,
may damage the pump, down stream equipment, and
bearings.
FIG. 16
vent hole