Graco G3 Series User manual

Conforms to ANSI/UL 73
Certified to CAN/CSA
Std. 22.2 No 68-09
3132066
24V and 110-240VAC Pumps ONLY
332291P
EN
Instructions
G3 Standard Automatic
Lubrication Pump
For dispensing of NLGI Grades #000 to #2 greases and oils 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 (34.3 MPa, 344.8 bar) Fill Inlet Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual before using the equipment.
Save these instructions.

2 332291P
Contents
Part / Model Numbers . . . . . . . . . . . . . . . . . . . . . . . 3
2 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
8 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
12 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 4
16 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Understanding the Model Number . . . . . . . . . . . 5
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 10
Typical Installation - With Remote
Fill Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 11
Optional Installation - Without Remote
Fill Manifold . . . . . . . . . . . . . . . . . . . . . . . . . 12
Choose an Installation Location . . . . . . . . . . . . 13
System Configuration and Wiring . . . . . . . . . . . 13
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pressure Relief Procedure . . . . . . . . . . . . . . . . . 19
Connect to Auxiliary Fightings . . . . . . . . . . . . . . 19
Set Pump Outlet Volume . . . . . . . . . . . . . . . . . . 20
Load Pump with Grease . . . . . . . . . . . . . . . . . . 20
Auto-Fill Shut Off . . . . . . . . . . . . . . . . . . . . . . . . 23
Fill the Oil Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Prime the Pump . . . . . . . . . . . . . . . . . . . . . . . . . 26
Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Recycling and Disposal . . . . . . . . . . . . . . . . . . . . . 29
End of Product Life . . . . . . . . . . . . . . . . . . . . . . 29
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Parts - 2 Liter Models. . . . . . . . . . . . . . . . . . . . . . . 32
Parts - 4 Liter and Larger Models . . . . . . . . . . . . . 33
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Mounting Pattern . . . . . . . . . . . . . . . . . . . . . . . . 38
Technical Specifications . . . . . . . . . . . . . . . . . . . . 40
California Proposition 65 . . . . . . . . . . . . . . . . . . 41
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 42

332291P 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 Num-
ber 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 the Model Number, page 5. The
tables below shows the relationship between each Part Number and its related Model Number.
2 Liter Models 4 Liter Models
Part
Numbers Model Number
96G000 G3-G-12NC-2L0000-00C00000
96G001 G3-G-24NC-2L0000-00C00000 X
96G002 G3-G-ACNC-2L0000-0D000000 X
96G003 G3-G-12NC-2L0A00-L0C00000
96G005 G3-G-24NC-2L0A00-L0C00000 X
96G006 G3-G-24NC-2LFA00-L0C00000 X
96G007 G3-G-ACNC-2L0A00-LD000000 X
96G008 G3-G-ACNC-2LFA00-LD00000 X
96G050 G3-A-24NC-2L0A00-L0C00000 X
96G059 G3-A-ACNC-2L0A00-LD000000 X
96G182 G3-G-24NC-2L0A00-0D00L000 X
96G239 G3-G-24NC-2L0A06-00C00000 X
96G243 G3-G-24NC-2L0A00-0D00L000 X
96G261 G3-G-24NC-2L0A07-L0C00000 X
Part
Numbers Model Number
96G038 G3-G-12NC-4L0L00-00C00000
96G040 G3-G-24NC-4L0000-00C00000 X
96G042 G3-G-ACNC-4L0000-0D000000 X
96G044 G3-G-12NC-4L0A00-L0C00000
96G048 G3-G-24NC-4L0A00-L0C00000 X
96G051 G3-A-24NC-4L0A00-L0C00000 X
96G053 G3-G-24NC-4LFA00-L0C00000 X
96G055 G3-G-ACNC-4L0A00-LD000000 X
96G060 G3-A-ACNC-4L0A00-LD000000 X
96G062 G3-G-ACNC-4LFA00-LD000000 X
96G173 G3-G-ACNC-4LFA00-0D00L000 X
96G179 G3-G-ACNC-4LFA00-0D00L000 X
96G184 G3-G-24NC-4L0A00-0D00L000 X
96G210 G3-G-24NC-4LAA00-0D00L000 X
96G180 G3-G-24NC-4L0A02-L0C00000 X
96G202 G3-G-ACNC-4L0A00-0D00L000 X
96G204 G3-G-24NC-4LFA00-0D00L000 X
96G238 G3-G-24NC-4L0A06-00C00000 X
96G248 G3-G-24NC-4L0A02-L0C00000 X
96G250 G3-G-24NC-4LFA07-0D00L000 X
96G273 G3-G-12NC-4L0A10-00C00000
96G276 G3-G-24NC-4L0A07-0D00L000 X
96G277 G3-G-24NC-4LLA06-00C00000
96G278 G3-G-24NC-4LHA06-00C00000
96G280 G3-G-24NC-4LHA00-0D00L000
96G287 G3-G-24NC-4L0A10-00C00000

4 332291P
8 Liter Models 12 Liter Models
16 Liter Models
Part
Numbers Model Number
96G039 G3-G-12NC-8L0000-00C00000
96G041 G3-G-24NC-8L0000-00C00000 X
96G043 G3-G-ACNC-8L0000-0D000000 X
96G045 G3-G-12NC-8L0A00-L0C00000
96G049 G3-G-24NC-8L0A00-L0C00000 X
96G052 G3-A-24NC-8L0A00-L0C00000 X
96G056 G3-G-ACNC-8L0A00-LD000000 X
96G061 G3-A-ACNC-8L0A00-LD000000 X
96G187 G3-G-ACNC-8LFA00-0D00L000 X
96G189 G3-G-24NC-8L0A00-0D00L000 X
96G192 G3-G-24NC-8LFA00-L0C00000 X
96G198 G3-G-24NC-8L0A06-0C000000 X
96G207 G3-G-ACNC-8LAA00-LD000000 X
96G213 G3-G-24NC-8LAA00-0D00L000 X
96G217 G3-G-24NC-8LAA06-00C00000 X
96G205 G3-G-24NC-8LFA00-0D00L000 X
96G233 G3-G-12NC-8L0A00-0D00L000
96G262 G3-G-24NC-8LLA06-00C00000
96G249 G3-G-24NC-8L0A07-0D00L000 X
96G251 G3-G-24NC-8LFA07-0D00L000 X
96G271 G3-G-24NC-8LFA07-00C00000 X
96G272 G3-G-24NC-8LFA10-00C00000
96G279 G3-G-24NC-8LHA06-00C00000
96G281 G3-G-24NC-8LHA00-0D00L000
96G290 G3-G-24NC-8LAA10-00C00000
Part
Numbers Model Number
96G057 G3-G-ACNC-120A00-LD000000 X
96G171 G3-G-24NC-120000-00C00000 X
96G199 G3-G-24NC-120A00-L0C00000 X
96G240 G3-G-24NC-120A00-0D00L000 X
Part
Numbers Model Number
96G058 G3-G-ACNC-160A00-LD000000 X
96G172 G3-G-24NC-160000-00C00000 X
96G220 G3-G-24NC-160A00-L0C00000 X
96G230 G3-G-12NC-160A00-0D00000
96G237 G3-G-ACNC-16AA00-LD000000 X
96G241 G3-G-24NC-160A00-0D00L000 X
96G258 G3-A-24NC-160A00-L0C00000 X

332291P 5
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: Other pump configurations are available that are not documented in this manual. 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
• NC = No 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
• H = Hammer Pump
Code f: Low Level Option
• A = External Low Level
• 0 = No Low Level monitoring
Code gg: Options
• 00 = No Options
• 06 = Low Level in CPC
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
• L = Low Level
• 0 = Not populated
G 3 - - N C 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
p
q
i
k
j
h

Warnings
6 332291P
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 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.

Warnings
332291P 7
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
8 332291P
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
332291P 9
Installation
Component Identification
Key:
A Reservoir
B Adjustable Pump Element (1 included. Can
accommodate 3 total)
C Pressure Relief Valve (Not included (not shown) / required
for each outlet - Available from Graco. See Parts, page
35.)
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. 18, page 20)
G Fuse (DC models only - Not included, not shown.
Available from Graco. See Parts, page 34.)
H Power / Sensor Panel (both sides; only one side shown)
I Part Number / Model Number example only shown, (see
page 5, Understanding the Model Number, for details)
J Power Cord (Not shown)
K Follower Plate (grease models only / not available on all
grease models)
L Vent Hole for Follower Plate (grease models only / not
available on all grease models)
M Fill cap (oil models only)
N Auto-Fill Shut Off
P Top Fill Lid
FIG. 2
A
D
H
E
I
G3-G-24NC-2L0A00-L0C00000
96GXXX
P
M
Grease Models
Auto-Fill Shut Off Models
N
F
B
K
L
Grease Models with
Follower Plate
Oil Models Top Fill Models

Installation
10 332291P
Typical Installation
Series Progressive Divider Valve
Injector Installations
Key
A Connected to fused power source
B Pressure relief valve (Not included/ required for each out-
let - user supplied. See Parts, page 35)
C Supply Hose (user supplied)
D Series progressive divider valves (Divider Installations)
- Injectors (Injector Installations)
E To lube points
F - Proximity Switch (Divider Installations)
- Pressure switch (Injector Installations)
G Vent valve (Not included / available from Graco. See
Parts, page 36.)
H Return to reservoir
FIG. 3
FIG. 4
A
B
DE
F
C
A
B
D
E
F
H
G
C

Installation
332291P 11
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. 5
E
D
C
F
P
N
K
HJ
M
L
A
R
Q
B
S
T

Installation
12 332291P
Optional Installation - Without Remote Fill Manifold
The installation shown is only a guide for selecting and installing system components. Contact your Graco distribu-
tor 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. 6
E
F
J
S
B
C
D
A
L1
HU
V
L
L2
W
Y

Installation
332291P 13
Choose 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 38. 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 models so that there is
a 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 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 5, Understanding the Model Num-
ber 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 isola-
tion at mounting point is necessary. See table
below.
• AC pumps are not recommended when high
vibration or shock is present.
System Configuration and
Wiring
Grounding
If the product is permanently connected, it must be:
• installed by a qualified electrician or serviceman.
• connected to a grounded, permanent wiring sys-
tem.
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.
AUTOMATIC SYSTEM ACTIVATION HAZARD
The system is equipped with an automatic timer that
activates the pump lubrication system when power
is connected or when exiting the programming func-
tion. 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
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.

Installation
14 332291P
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 con-
nector does not exit the unit in the UP direction.
• Use a corrosion preventative electrical grease on all
contacts.
Wire and Installation Diagrams
The following table identifies the wiring and installation
diagrams for the cables included with the pump.
Power DIN AC - 15 foot
Pin and Related Wire Color (FIG. 7)
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
Diagram Symbol Page
Power DIN AC 14
Power DIN DC 15
Power CPC DC 15
Low Level Outputs 16
Pin Pin Name Color
1 Line Black
2 Neutral White
3 Not Used Not Used
4Ground Green
FIG. 7

Installation
332291P 15
Power DIN DC - 15 foot
Pin and Related Wire Color (FIG. 8)
Power CPC DC - 15 foot
Pin and Related Wire Color (FIG. 9)
Pin Pin Name Color
1 -VDC Black
2 +VDC White
3 Not Used Not Used
4Not Used Green
FIG. 8
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. 9

Installation
16 332291P
Power CPC DC - With Low
Level
Pin and Related Wire Color (FIG. 10)
Low Level Outputs
See Low Level Output Option, page 27 for functional
description. See Technical Specifications, page 40 for
ratings.
Pins (FIG. 11)
Pins (FIG. 12)
Pin Pin Name Color
1 Not Used Not Used
2 -VDC Black
3 +VDC Red
4 LL N.O. White
5 LL COM Orange
6 Not Used Not Used
7 Not Used Green
FIG. 10
Pin Pin Name
1 Not Used
2 Not Used
3 LL N.O.
4 LL COM
FIG. 11
Pin Pin Name
1 LL N.O.
2 Not Used
3 LL COM
4 Not Used

Installation
332291P 17
Part No. 124333: Cable Pin Out (M12)
Wire Colors (FIG. 13)
Part No. 124300: Field Wireable Pin Out
(M12)
Wire Colors (FIG. 14)
FIG. 12
Item No. Color
1 Brown
2 White
3 Blue
4 Black
FIG. 13
Item No. Color
1 Brown
2 White
3 Blue
4 Black
FIG. 14

Installation
18 332291P
Part No. 124594: 4 Pin Eurofast Male Field
Wireable Connector (FIG. 15)
Part No. 124595: 5 Pin Eurofast Male Field
Wireable Connector (FIG. 16)
FIG. 15
FIG. 16

Setup
332291P 19
Setup
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
Relieve pressure at the pump element using two
wrenches working in opposite directions on the pump
element and pump element fitting to slowly loosen fit-
ting only until fitting is loose and no more lubricant or air
is leaking from fitting. Repeat for each pump element
installed (FIG. 17).
NOTE: When loosening pump element fitting, do not
loosen pump element. Loosening pump element will
change the output volume.
Connect to Auxiliary Fightings
Pressure Relief Valves
NOTE: A pressure relief valve can be purchased from
Graco. See Parts, page 35.
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. 17
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. 17 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 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. See Technical
Data, page 33.
• Install a pressure relief valve close to every
pump outlet; before any auxiliary fitting.

Setup
20 332291P
Set Pump Outlet Volume
NOTE:
• 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. Follow the Pressure Relief Procedure, page 19,
before making any adjustments to the pump
volume.
2. Use a wrench to turn the pump element counter-
clockwise to loosen. Do not remove the entire
pump element. Only back the pump element out
enough to allow a spacer to be slid on or off. (FIG.
18).
3. If needed, remove or insert spacers to achieve the
required pump output volume. A tool may be
needed to facilitate removal.
The pump volume control is set using no spacers,
one (1) or two (2) spacers (FIG. 18).
Do not use more than two (2) spacers to adjust the
output volume.
4. Tighten the pump element fitting. Torque fitting to
50 in. lbs. (5.6 N•m).
• The amount of dispensed volume varies depending
upon external conditions, such as lubricant
temperature and back pressure from downstream
connections.
• 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 needed to ensure the desired
lubrication 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
temperature. Consult with the machine and lube
manufacturer for details.
• The reservoir can be filled using a hand operated
pump, a pneumatic pump, or an electric transfer
pump.
• Do not overfill the reservoir.
• Do not operate the G3 pump without a reservoir
attached.
FIG. 18
No. Spacers
Output Volume / Minute
cubic inches cubic cm
2 0.12 2
1 0.18 3
0 0.25 4
NOTICE
• Always clean the fitting (D) (FIG. 19) with a clean
dry cloth prior to filling the reservoir. Dirt and/or
debris can damage the pump and/or the lubrica-
tion system.
• When changing greases, always use compatible
fluids or greases.
• Use care when filling the reservoir with a pneu-
matic or an electric transfer pump, to not pressur-
ize and break the reservoir.