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1 2525 GARDNER ROAD, BROADVIEW, IL Outside U.S G3 SERIES ELECTRIC POWER PUMP PARTS IDENTIFICATION MANUAL Reference # Rev. - A Date - 10/08 This illustration is for reference purposes only. The appearance of your unit may differ from the unit shown. Electrical Brackets Wiring Diagrams - pg Valve Sub-Assemblies - pg Manifold Sub-Assemblies - pg Common Components used in all G3 Series pumps - pg. 3-5 Pump Sub-Assemblies and Sub-Components - pg. 6-9 Reservoirs - pg. 20

2 How to Identify Parts for Your Model. MODEL MATRIX Understanding our model number configurations: PUMP CLASS Sample Model #: G L M R Model Performance Series Power Consumption Valve Function Reservoir Size Description: 0 = Dump 0 = 1 Gal Plastic G = Gen II Pump 1 = 115 VAC 3 = HP 1 = Dump 2 Way 1 = 1 Gal Metal 2 = 2 Way Manual 2 = 1.5 Gal 2 = 230 VAC 3 = 3 Way Manual 3 = 2.5 Gal 4 = 4 Way Manual 5 = 5 Gal 5 = 2 Way Solenoid 6 = 3 Way Solenoid 7 = 4 Way Solenoid 8 = Port Block PUMP TYPE OPTION 1 Options OPTION 2 C = Caster Wheel Kit D = Dig. Pressure Gauge F = Foot Switch (motor) G = Gauge (intergrated) H = Heat Exchanger L = Locking Style Manifold M = Motor Pendant O = Oil Filter P = Pressure Switch R = Roll Cage S = Foot Switch (valve) OPTION 3 MODEL NUMBER & DATE CODE LOCATION DATE CODE COVER PLATE STAMPING LOCATION MODEL DECAL PLACEMENT

3 Common components used in pumps NOTE: This illustration is for reference only. The appearance of your unit may differ from unit shown. 3

4 Common components used in pumps CONTINUED... 4

5 Common components used in pumps ITEM # DESCRIPTION 115 V. 230 V. QTY. ITEM # DESCRIPTION 115 V. 230 V. QTY. 03 RESERVOIR BLACK SEE PAGE HEAVY HEX JAM NUT 1/ RESERVOIR GASKET * BHCS x 3/8 LG BREATHER VENT 3/8" NPT SIMPLEX DECAL 5.71" x 1.15" PIPE PLUG 1/4" W/ COATING BRACKET SUPPORT G SAE #12 HEX PLUG WI PORT PENDANT ASSEMBLY BASIC HHCS 1/4-20 X.75 PLT HOLE PLUG 1/4" SEALING WASHER SPACER 1.5" LONG G3 RESERVOIR DECAL HHCS 1/4-20 X LABEL SAFE USE ELEC WASHER 1/4" SS BLANK DECAL 3 X COIL 115V WITH DIN CONN MANIFOLD ASM SEE PAGE MOLDED DIN CONN W/ CORD VALVE GASKET SIGHT GAUGE SHCS 3/8-16 X 2 1/ MEMBRANE SWITCH LABEL ADAPTER ASSY DECAL PENDANT INSTRUCTION HEX PIPE PLUG 3/8" W/ COAT SIMPLEX DECAL 1.25" x 0.25" HEX PIPE PLUG 3/8" W/ COAT PUSH THRU BUSHING VALVE ASM VELCRO STRAP 1x **20 SHCS 3/8-16 X 3 1/ HOLE PLUG 7/8" **21 LOCK WASHER 3/ MOTOR GASKET G3 * * 1.00 **22 ROLL PIN 1/8 X 3/8 LG GASKET PUMP * * WY RET VLV DECAL COVER PLATE SEE PAGE MAGNET * * SHCS #10-24 X 5/8" <25> MOTOR SHROUD W/ HANDLE SHCS #10-24 X 1" LG HOSE CLAMP G3 MOTOR 1.5HP 115V DECAL OVERLAY FHCS X 0.50LG BRACKET ASSEMBLY SEE PAGE SHCS #10-32 X FOAM INSERT NOTES : <25> 5 AND 10 GALLON USE MOTOR SHROUD WITHOUT HANDLE PART # **20. **21. **22. COMPONENTS ONLY USED WITH ELECTRIC VALVES WAY LOCK VALVES USE VALVE GASKET # G SERIES PENDANT DECAL KIT (+ + = COMPONENTS) -- PART # G 3 REBUILD KIT ( * = COMPONENTS) -- PART #

6 Pump Assembly (46541) PUMP ASM. ITEM # DESCRIPTION PART # QTY. 01 GEAR SECTION ASSEMBLY SEE PAGE PUMP VALVE SECTION ASSEMBLY SEE PAGE SHCS 5/16-24 X 1" LG PISTON BLOCK TUBE G

7 Gear Section Assembly (45535) GEAR SECTION ASM. 7

8 Gear Section Assembly (45535) GEAR SECTION ASM. ITEM # DESCRIPTION PART # QTY. 01 G3 PUMP BODY 2 PISTON TUBE-GUIDE SHCS 1/4-28 X 1 1/ SET SCREW #10-24 X 1/4 CUP O-RING 5/16X7/16 * SHCS 1/4-28 X 1.25LG POW'R BUD REDUC GEAR POW'R BUDDY PUMP SHAFT ROLL BRG 3/4ID X 5/ POW'R BUD ECC RING ROLL BRG 1 1/8 X 3/ BEARING ROLLER 1/2x11/16x1/2 WIDE O RING 1/4X3/8 * GEAR-PUMP BALL 1/8" BEARING ROLLER 1/2x11/16x1/2 WIDE BOTTOM PLATE 3/8" GEARS G POW'R BUDDY WEAR PLATE POW'R BUDDY ECCENCTRIC RING THRUST WASHER 3/4"ID THRUST BRG 3/4" ID POW'R BUDDY IDLER SHAFT RING-RETAINING WASHER 1/4" SS POW'R BUDDY SCREEN * O-RING 3/16X5/16 * PISTON BLOCK ASSEMBLY #1 G3 SEE PAGE PISTON BLOCK ASSEMBLY G3 SEE PAGE SHCS 5/16-24 X BALL 3/16" G3 PISTON BLOCK TUBE O-RING 3/8X1/ * G 3 REBUILD KIT (* = COMPONENTS) -- PART #

9 Pump Valve Section Assembly (46025) PUMP VALVE SECT ASM. ITEM # DESCRIPTION PART # QTY. 01 PB VALVE BODY SECT BALL 5/16" SPRING GASKET 25/64X19/32 * SCREW, BALL STOP MALE ELBOW 1/8 PIPE UNLOADING PISTON ASM Page BALL 11/32" SPRING UNLOADING VLV O-RING 3/8X1/2 * ADJUSTING SCREW /16 SOC PIPE PLUG O-RING 3/16X5/16 * BACKUP WASHER POW'R BUD DUMP PLUG /4 SOC PIPE PLUG SEAT - EXT RELIEF CONE - EXT RELIEF SPRING - RELIEF VALVE ROLL PIN 1/8X15/ PLUG SAE # G 3 REBUILD KIT (* = COMPONENTS) -- PART # RELEIF REPLACEMENT KIT ( ++ = COMPONENTS) -- PART #

10 Sub Component Assemblies (45533) PISTON BLK ASM. ITEM # DESCRITPION PART # QTY. 01 GEN II PISTON BLOCK BALL 1/8" SPRING BALL STOP BALL RETAINER INTAKE SEAT GASKET 29/64 X 5/8 * PLUG PISTON BLOCK GASKET 25/64X19/32 * ADAPTER-.290 PISTON SPRING, PISTON PISTON-.290 DIA MALE TEE 1/8" PIPE 1/4" TUBE (45538) PISTON BLK ASM. ITEM # DESCRIPTION PART # QTY. 01 PISTON BLOCK BALL 1/8" SPRING BALL STOP BALL RETAINER INTAKE SEAT GASKET 29/64 X 5/8 * PLUG PISTON BLOCK GASKET 25/64X19/32 * ADAPTER-.290 PISTON SPRING, PISTON PISTON 0.290" DIA MALE ELBOW 1/8 PIPE (43687) UNLOADING PISTON ASM. ITEM # DESCRITPION PART # QTY. 01 UNLOAD PISTON O RING 1/4X3/8 * BACK-UP WASHER DOWEL PIN 1/8X3/4 LG G 3 REBUILD KIT ( *= COMPONENTS) -- PART #

11 Valve Sub Assembly (69094) 2 WAY MANUAL (69101) 4 WAY MANUAL (69691) 3 WAY MANUAL PART# ITEM # DESCRIPTION 2 WAY VAL. QTY WAY VALVE BALL VALVE STEM O-RING BACKUP WASHER SCREW VALVE HANDLE ROLL PIN SEAT - EXT RELIEF CONE - EXT RELIEF SPRING - RELIEF VALVE ACORN NUT WASHER ADJUSTING SCREW ADAPTER ASSY SPRING NS PIPE PLUG /4 SOC PIPE PLUG HEX ST. PIPE PLUG SPRING CAP LOCKWASHER Y NS = NOT SHOWN RELEIF REPLACEMENT KIT ( ++ = COMPONENTS) -- PART # ITEM # DESCRIPTION 3 WAY VAL QTY. 4 WAY VAL QTY. 01 VALVE ROTOR O-RING * 2.00 * SUBPLATE- VALVE O-RING * 1.00 * THRUST WASHER THRUST BEARING O-RING * 1.00 * UPPER VALVE BLOCK DRIVE LOK PIN O-RING * 6.00 * WASHER * 4.00 * SHEAR SEAL SPRING WASHER DETENT SPRING BALL VALVE HANDLE SCREW SCREW NS SCREW O-RING * 1.00 * SHEAR SEAL LOCKWASHER Y Y PACKING KIT 3 & 4 WAY MANUAL VALVE ( * = COMPONENTS) -- PART #

12 Valve Sub Assemblies (46285) 3 & 4 WAY SOLENOID VALVE 115V. (46295) 3 & 4 WAY SOLENOID VALVE 230V. PART # ITEM # DESCRIPTION 115 V. 230 V. QTY. 01 BODY-VALVE SLIDER TANDEM CENTER BALL 3/16" SET SCREW 1/4-28 X 1/4 CUP O-RING 7/32X11/32 * * BACK UP WASHER * * SHEAR SEAL SPRING O-RING 2 5/8 X 2 3/4 * * BEARING ROLLER 5/16x1/2x5/16 WIDE PIN BEARING PIPE PLUG FLUSH 1/16 W/ COATING SHCS #10-32 X 1" LG PLATED VALVE TOP PLATE MACHINED O-RING 3/16X5/16 * * O-RING SAE PORT #10 * * SPRING O-RING 5/16X7/16 URE * * PUSHER-SOLENOID PACKING KIT 3 & 4 WAY SOLENOID VALVE (* = COMPONENTS) -- PART #

13 Manifold Sub Assemblies (69570) 3 WAY STANDARD PART# PART# ITEM# DESCRIPTION 3 WAY MAN. ASM QTY. ITEM# DESCRIPTION 3 WAY MAN. ASM QTY. 01 RET. VALVE MANIFOLD NS PIPE PLUG NOZZLE-VALVE PIPE PLUG-FLUSH SEAT - EXT RELIEF * O-RING CONE - EXT RELIEF * WASHER SPRING - RELIEF VALVE * ACORN NUT ADJUSTING SCREW NS = NOT SHOWN RELEIF REPLACEMENT KIT (* = COMPONENTS) -- PART # (69100) 4 WAY STANDARD PART# PART# ITEM# DESCRIPTION 4 WAY MAN. ASM QTY. ITEM# DESCRIPTION 4 WAY MAN. ASM QTY. 01 VALVE MANIFOLD SPRING - RELIEF VALVE * ADJUSTING SCREW CONE - EXT RELIEF * ACORN NUT SEAT - EXT RELIEF * WASHER PIPE PLUG RELEIF REPLACEMENT KIT (* = COMPONENTS) -- PART #

14 Manifold Sub Assemblies (68581) 4 WAY LOCKING PART # PART # ITEM # DESCRIPTION 3 WAY LOCK QTY. ITEM # DESCRIPTION 4 WAY LOCK QTY. 01 VALVE BODY LOCK VAL SPRING - RELIEF VALVE BALL CONE - EXT RELIEF RELEASE GLAND SEAT - EXT RELIEF O-RING * BU-WASHER * RELEASE SCREW ASM BALL RETAINER O-RING * O-RING BALL SPOOL-LOCK VALVE O RING * SEAT RELIEF VALVE ADJ SCREW PIPE PLUG RELEIF REPLACEMENT KIT (++ = COMPONENTS) -- PART # PACKING KIT 3 & 4 WAY LOCK VALVE (* = COMPONENTS) -- PART #54492 (69621) 3 WAY LOCKING PART# PART# ITEM# DESCRIPTION 3 WAY LOCK QTY. ITEM# DESCRIPTION 4 WAY LOCK QTY. 01 VLV BODY LOCKING GASKET-PLUG SEAT - EXT RELIEF PLUG-SPOOL CONE - EXT RELIEF BALL SPRING - RELIEF VALVE GASKET WASHER SCREW PORT ADAPTER WASHER ACORN NUT RETAINING SLEEVE NOZZLE-VALVE O RING * PIPE PLUG 3/8" BACK-UP WASHER * PIPE PLUG 1/8" O-RING * 1.00 NS 1/16 PIPE PLUG HEX ST. PIPE PLUG COMPRESSION SPRING SPOOL LOCTITE PACKING KIT 3 & 4 WAY LOCK VALVE (* = COMPONENTS) -- PART #54492 RELEIF REPLACEMENT KIT (++ = COMPONENTS) -- PART #

15 Bracket Sub Assemblies (46488) BRACKET SUB ASM. 115V. ITEM # DESCRIPTION PART# QTY. ITEM # DESCRIPTION PART# QTY. 01 MOUNTING BRACKET G3/G WIRE #14 BLACK 68261B PLUG AND CORD ASSY QUICK DISCON. FLAG BLUE CIRCUIT BOARD BASIC RING TERMINAL 1/4" BRIDGE RECTIFIER 25A SHCS #10-32X1/4" LG PLATED SHCS #10-32 X 1/ GROMMET 7/8" HOLE FITTING,CORD L-TIGHT FUSE HOLDER 30 AMP LOCKNUT 1/2 INCH FUSE 25 AMP MACHINE SCR W/ LOCK WASH# SHCS #6-32 x 1/4 LONG HHCS 1/4-20 X.75 PLT SPADE TERMINAL HEX NUT 1/4-20 PLATD STRAIN RELIEF 3/8 NPT LOCKNUT 3/8 NPT

16 Bracket Sub Assemblies (46489) BRACKET SUB ASM. 230V. ITEM # DESCRIPTION PART # QTY. ITEM # DESCRIPTION PART # QTY. 01 MOUNTING BRACKET G3/G WIRE #14 BLACK 68261B POWER CORD 14-3 IEC 69604R QUICK DISCON. FLAG BLUE PLUG 20 AMPS-250V RING TERMINAL 1/4" CIRCUIT BOARD BASIC SHCS #10-32X1/4" LG PLATED BRIDGE RECTIFIER 25A GROMMET 7/8" HOLE SHCS #10-32 X 1/ FUSE HOLDER 30 AMP FITTING,CORD L-TIGHT FUSE 12 AMP LOCKNUT 1/2 INCH SHCS #6-32 x 1/4 LONG MACHINE SCR W/ LOCK WASH # SPADE TERMINAL HHCS 1/4-20 X.75 PLT STRAIN RELIEF 3/8 NPT HEX NUT 1/4-20 PLATD LOCKNUT 3/8 NPT

17 Wire Configurations MANUAL CONTROL WIRING DIAGRAM 115V. SET INPUT POWER SWITCH TO THE LEFT FOR 115 V.. MANUAL CONTROL WIRING DIAGRAM 230V. SET INPUT POWER SWITCH TO THE RIGHT FOR 230 V.. 17

18 Wire Configurations MANUAL MOTOR CONTROL WIRING DIAGRAM 115V. SET INPUT POWER SWITCH TO THE LEFT FOR 115V. MANUAL MOTOR CONTROL WIRING DIAGRAM 230V. SET INPUT POWER SWITCH TO THE RIGHT FOR 230 V.. 18

19 Wire Configurations SOLENOID CONTROL WIRING DIAGRAM 115V. SET INPUT POWER SWITCH TO THE LEFT FOR 115V. SOLENOID CONTROL WIRING DIAGRAM 230V. SET INPUT POWER SWITCH TO THE RIGHT FOR 230 V.. 19

20 Reservoirs (46109P) 1.0 GALLON RESERVIOR (45996P) 1.5 GALLON RESERVIOR (46213P) 2.5 GALLON RESERVIOR (46046P) 5.0 GALLON RESERVIOR GALLON RESERVOIR NOTE: THIS ILLUSTRATION IS FOR REFERENCE ONLY. THE APPEARANCE OF YOUR UNIT MAY DIFFER FROM UNIT SHOWN. 3 ITEM # DESCRIPTION 1.0 GALLON QTY. 1.5 GALLON 2.5 GALLON 5.0 GALLON QTY. 03 RESERVOIR 46109P P 46213P 46046P RESERVOIR GASKET BREATHER VENT 3/8" NPT /4 SOC PIPE PLUG SAE #12 HEX PLUG WITH PORT N/A HHCS 1/4-20 x 3/4 LG PLATED SEALING WASHER G3 RESERVOIR DECAL SIGHT GAUGE COVER PLATE NOTE: ALL RESERVOIRS ARE POWDER COATED BLACK. FOR 1 GALLON PLASTIC RESERVOIRS, PLEASE ORDER PART #

21 2525 GARDNER ROAD, BROADVIEW, IL Outside U.S UNITED STATES HOME OFFICE AND FACTORY 2525 Gardner Road, Broadview, IL Phone: (708) Fax: (708) Toll Free: (800) SIMPLEX PRODUCTS ARE WARRANTED TO BE FREE OF DEFECTS IN MATERIALS AND WORKMANSHIP UNDER NORMAL USE FOR AS LONG AS THE ORIGINAL PURCHASER OWNS THEM, SUBJECT TO THE GUIDELINES AND LIMITATIONS LISTED. THIS WARRANTY DOES NOT COVER : NORMAL WEAR AND TEAR, COSMETIC ITEMS, ABUSE, OVERLOADING, ALTERATIONS. IMPROPER FLUID, OR USE IN A MANNER FOR WHICH THEY ARE NOT INTENDED. IF THE CUSTOMER BELIEVES A PRODUCT IS DEFECTIVE, THE PRODUCT MUST BE DELIVERED, OR SHIPPED FREIGHT PREPAID, TO THE NEAREST SIMPLEX AUTHORIZED SERVICE CENTER FOR EVALUATION AND REPAIR. Printed in the U.S.A.

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