Page 1
Instructions
Grease Jockey
Lubrication Controller
334662B
For controlling and monitoring an automated lubrication system.
Not approved for outdoor use or use in explosive atmospheres or hazardous locations.
Model: 24W482
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
EN
Page 2
Warnings
WARNINGWARNINGWARNING
WARNING
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.
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 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.
2 334662B
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Component Identification
F
B
A
C
E
D
Keypad, Display, and Icons
Component Identification
NOTICE
To prevent damage to soft key buttons, do not press
the buttons with sharp objects such as pens, plastic
cards, or fingernails.
RIGHT Direction Arrow / TEST / ENTER (D)
• In SETUP MODE, saves entry, moves cursor in
display one field to the right or to the next setup
step.
• In RUN MODE activates the pump for one complete ON cycle if actuated during the OFF portion of the RUN cycle.
UP and DOWN Direction Arrows (E)
• Press and hold both the UP and DOWN Arrow
keys together for 3 seconds to enter SETUP
MODE.
• In SETUP MODE increase or decrease number
values associated with operation.
LEFT Direction Arrow / TEST / RESET (F)
• In SETUP MODE moves cursor in display one
field to the left.
• In RUN MODE, Pressing RESET starts a PUMP
OFF cycle.
FIG. 1
Pump ON LEDs (A)
• Time Control LED: In RUN MODE illuminates
indicating function mode that is currently running.
Pump OFF LED (B)
• In RUN MODE this LED illuminates when in the
OFF or RESET portion of the RUN CYCLE.
Display (C)
• A blinking field on the display indicates the controller is in SETUP MODE.
• In RUN MODE numbers on the display will not
blink.
• Press and hold left and right direction arrow
together for 3 seconds to enter TEST MODE.
334662B 3
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Installation
Pump
Solenoid
Timer
Fuse (user supplied)
Red
+Ignition
Black
Ground
Wiring
Harness
Mating Harness
Installation
The installation shown in FIG. 2 is only a guide for selecting and installing system components. Contact your Graco
distributor for assistance in planning a system to suit your needs.
FIG. 2
4 334662B
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System Wiring
a
a
AUTOMATIC SYSTEM ACTIVATION HAZARD
Unexpected activation of the system could result in serious injury, including skin injection and amputation.
This device has an automatic timer that activates the
pump lubrication system when power is connected or
when exiting the programming function. Before you
install or remove the Lubrication Controller from the
system, disconnect and isolate all power supplies and
relieve all pressure.
Timer Installation
1. Connect timer leads to solenoid. A wiring harness
kit with a mating connector is available from your
Graco distributor.
Installation
Mating Harnesses
127899 - 8 inch harness with DELPHI 56 connector
127900 - 8 inch harness with DELPHI 280 connector
24P314 - 5 foot harness with flying leads
NOTE: All connections between timer and solenoid
must be moisture-proof and safe from grounding.
NOTICE
Do not ground the yellow wires to the solenoid. This
could cause damage to the timer.
2. Connect the red lead wire to the positive side of the
vehicle ignition switch. Install a 5 amp fuse at this
connection.
3. Connect the black lead wire to the chassis ground.
FIG. 3
Installing the Lubrication Controller
1. Select a flat surface to install the Lubrication Controller. Drill mounting holes. Refer to Mounting Hole
Layout Provided in the Technical Data section of this
manual, page 13.
2. Align junction box with predrilled holes (F
Use two screws (not provided) to secure junction
box to mounting surface.
334662B 5
IG. 4, (a).
FIG. 4
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Setting Up a Personal Identification Number (PIN) (Optional)
Setting Up a Personal Identification Number (PIN)
(Optional)
Setup Code A1 is available to secure the setup modes with a PIN. A required PIN provides the system with added
security by preventing unauthorized users from making adjustments to the settings. A PIN is not required.
Entering a PIN Code for the First Time
A1-Setting Up PIN Code
A PIN Code can be programmed into the Grease Jockey
Controller to protect the settings from inadvertently
being changed by unauthorized users.
1. Press the UP ARROW button for 3 seconds.
2. Press the ENTER button to select
the A1 option.
3. Press the UP or DOWN
ARROW button to change
this to ON.
4. Press the ENTER button to enter
the PIN Code.
5. Use the UP and DOWN
ARROW buttons to move up
and down through the numbers 0-9 until the first number
in the PIN code is displayed in the field.
Entering Advanced Setup
Press the UP ARROW button for 3 seconds.
If the Grease Jockey Controller was previously set up to require a PIN Code:
1. Use the UP and DOWN
ARROW buttons to move up
and down through the numbers 0-9 until the first number
in the PIN code is displayed in the field.
2. Press the ENTER button to set the
number. The cursor automatically
moves to the next number field.
3. Repeat steps 1 and 2 for each PIN
Code prompt field.
6. Press the ENTER button to set the
number. The cursor automatically
moves to the next number field.
7. Repeat steps 5 and 6 for each PIN Code prompt
field.
8. Press the ENTER button to save the
PIN Code and exit Advanced Setup.
6 334662B
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Setup
Setup
Entering SETUP MODE
Press both the UP and DOWN ARROW buttons
together for three seconds.
If the Grease Jockey Controller was previously set up to
require a PIN Code:
a. Use the UP and DOWN
ARROW buttons to move
up and down through the
numbers 0-9 until the first
number in the PIN code is displayed in the field.
b. Press the ENTER button to set
the number. The cursor automatically moves to the next
number field.
c. Repeat steps 1 and 2 for each PIN Code prompt
field.
NOTE:
• If a button is not pushed for 1 minute, the controller
resumes operation.
Time Control (on:ti) ON Setup
1. on:ti is on the display.
2. Press ENTER.
3. To set the ON time use the UP or
DOWN ARROW to scroll through the numerals 0-5
until the desired number appears in the first Minutes
(MM) field.
NOTE:
• The MM field is a 2-digit number.
• A leading zero (0) must be entered in the first
field if the number of minutes is fewer than 10.
• The highest number that can be set for the MM
field value is 59.
4. Press the ENTER button.
The next MM number field to the right flashes, indicating
it is ready for programming.
• Setting changes are not stored unless programming
is completed and setup mode is exited normally by
pressing the ENTER button.
• A blinking dot below the HH, MM, or SS indicates
the field currently being programmed.
Programming ON Duration
• on:ti appears on the display identifying the function
you are programming (see below).
• The illuminated LED below the related symbol on
the controller label also indicates the function.
• on:ti = Time Control, a spe-
cific duration of time elapses
5. Use the UP or DOWN ARROW to scroll through the
numerals 0-9 until the desired number appears in
the second MM number field.
6. Press the ENTER button.
The next number field to the right flashes indicating it is
ready to program the Seconds (SS) fields.
NOTE:
• The Seconds (SS) field is a 2-digit number.
• A leading zero (0) must be entered in the first
field if the number of seconds is fewer than 10.
• The highest number that can be set for the SS
field value is 59.
7. Repeat steps 3 - 6 to set the SS fields.
8. Press the ENTER button. After you press the
ENTER button the controller automatically switches
to the OFF TIME SETUP MODE.
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Page 8
Setup
Programming OFF TIME Duration
After setting the parameters for the Time (Ti) ON Mode,
the OFF TIME or PUMP REST CYCLE must be set up.
The LED below the OFF TIME Symbol Illuminates.
NOTE:
• The HH field is a 2-digit number.
• A leading zero (0) must be entered in the first
field if the number of hours is fewer than 10.
• The highest number that can be set for the HH
field value is 99.
To set the OFF Time:
1. Use the UP or DOWN ARROW to
scroll through the numerals 0-9 until
the desired number appears in the
first Hours (HH) field.
• The highest number that can be set for the MM
field value is 59.
5. Repeat steps 1 - 4 to set the MM fields.
6. Press the ENTER button to lock in
the last MM field.
NOTE: When the user exits SETUP
MODE:
• The display shows the firmware version.
• The controller goes to the beginning of a PUMP
OFF Cycle.
2. Press ENTER.
The next HH number field to the right
flashes, indicating it is ready for programming.
3. Use the UP or DOWN ARROW to
scroll through the numerals 0-9 until
the desired number appears in the
second HH field.
4. Press the ENTER button.
The next number field to the right
flashes indicating it is ready to program the Minutes (MM) fields.
NOTE:
• The MM field is a 2-digit number.
• A leading zero (0) must be entered in the first
field if the number of minutes is fewer than 10.
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Operation
Setup
Run Mode
The controller is in Run Mode providing the following circumstances are present:
• The controller is not in SETUP MODE.
• An Alarm is not active.
Timer Mode: Pump ON
The display indicates the amount of time remaining in
the pump cycle, counting down the Pump ON time value
(see Time Control (on:ti) ON Setup, page 7).
• The Pump output is enabled.
• Pump ON time is shown in MM:SS (minutes:seconds).
Timer Mode: Pump OFF
The display indicates the amount of time remaining in
the pump OFF cycle, counting down the Pump OFF time
value (see Programming OFF Time Duration, page 8).
Test Mode
To enter Test Mode:
1. Press the LEFT and
RIGHT ARROW
buttons together for
3 seconds.
2. The unit will cycle ON for 45 seconds and OFF for
15 seconds until the Test Mode is exited.
3. To exit Test Mode, press the Reset
button once.
• The Time OFF LED illuminates and the pump output
is disabled during the Pump OFF time.
• Pump OFF time is shown in HH:MM (hours:minutes)
or MM:SS if the time remaining is less than an hour.
334662B 9
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Troubleshooting
Troubleshooting
Description Problem Solution
Unit does not power on or display is
dim/unresponsive
Pump is not running during Pump ON
Incorrect or loose wiring
Input voltage is out of range Confirm power source is between 9
Tripped external fuse Confirm that none of the devices or
Incorrect or loose wiring Confirm current is being delivered to
Controller output is incorrect Confirm output voltage (PUMP+)
Refer to installation instructions
beginning on page 4.
and 30 VDC.
wiring connected to the controller are
causing a short circuit connection.
Replace fuse. If fuse trips again, contact Graco Customer Support.
the pump during pump ON. Refer to
installation instructions, page 4. Verify that your machine has been wired
correctly.
from controller during pump ON is
correct (should be similar to input
voltage).
Air solenoid failure Replace air solenoid.
Reservoir quickly and unexpectedly
runs out of grease
Test mode is engaged Turn off test mode.
Program Settings
Modes of Operation
Description
TIME ON, page 7 MM:SS (00:01 - 59:59)
TIME OFF, page 8 HH:MM (00:01 - 99:59)
Maximum / Minimum
NOTE: Measure at controller to
ensure there is not wiring issue causing the problem.
If controller output voltage is never
present, the device may need
replacement.
Recommended Timer Settings
NOTE: These are recommended settings only. Experience with individual applications will determine timer
setting.
Timer Setting Driving Conditions
1/2 or 1 hr Off Highway
Start and stop city, heavy salt, snow
1.5 or 2 hr
3 hr
and ice, rough pavement, wet climate,
heavy loads, dusty roads.
Normal city or highway driving, normal
climate, moderate loads.
10 334662B
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Parts
1
3
4
2
Ref. Description Qty
1 BOX, enclosure 1
2 LABEL, control, overlay 1
3 LABEL, serial, name 1
4 LABEL, connector 1
Parts
Accessories
Related Kits
Kit No. Description
127900 HARNESS, Grease Jockey, Delphi 280
127899 HARNESS, Grease Jockey, Delphi 56
24P314 CABLE, wiring harness
17C942 BRACKET, timer
334662B 11
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Technical Data
Technical Data
Input Contact
Power Source DC 9 - 32 VDC
Power Consumption 1 Watt
Outputs
Pump control Pump Control Voltage = Power Source
Voltage Pump Control Voltage = Power Source
Max Switching Voltage 32 VDC
Max Switching Current 9A (DC)
Min Switching Current 100 mA (DC)
Protection grade
Enclosure Material
Membrane Material
Maximum Humidity
Operating temperature range - 40°F to 176°F (- 40°C to 80°C)
Storage Temperature - 40°F to 176°F (- 40°C to 80°C)
IP54 for indoors and vehicle cab use
ABS
Polyester
90% RH (non-condensing)
12 334662B
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Dimensions
2.75 in. (70.0 mm)
5.53 in.
(140.0 mm)
1.38 in.
(35.0 mm)
1.57 in.
(40.0 mm)
4.92 in.
(125.0 mm)
2 x Ø
0.2 in.
(5.0 mm)-
Dimensions Mounting Hole Layout
334662B 13
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Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will
be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED
TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
For patent information, see www.graco.com/patents.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6928 or Toll Free: 1-800-533-9655, Fax: 612-378-3590
All written and visual data contained in this document reflects the latest product information available at the time of publication.
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 334662
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
www.graco.com
June 2015
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