Graco 312054J User Manual

Instructions – Parts

®

Grease Jockey
Chassis Lubrication

For on-board, automatic lubrication of trucks and heavy-use vehicles. For professional use
only.

Maximum Working Pressure: See Technical Data, page 24

Important Safety Instructions

Read all warnings and instructions in this
manual. Save these instructions.

312054J

EN

Bulletin GJ-30050

ti9447a

Warnings

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 symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.

WARNING

FIRE AND EXPLOSION HAZARD

When flammable fluids are present in the work area, such as gasoline and windshield wiper fluid, be
aware that flammable fumes can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources, such as cigarettes and portable electric lamps.

• Keep work area free of debris, including rags and spilled or open containers of solvent and gasoline.

• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.

• Ground all equipment in the work area.

• Use only grounded hoses.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment

until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

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 forms from distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu­facturer’s replacement parts only.

• Do not alter or modify equipment.

• 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.

ELECTRIC SHOCK HAZARD

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
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.

2 312054J

Warnings

WARNING

SKIN INJECTION HAZARD

High-pressure fluid from dispense valve, 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 dispense valve at anyone or at any part of the body.

• Do not put your hand over the end of the dispense nozzle.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,

checking, or servicing equipment.

MOVING PARTS HAZARD

Moving parts can pinch 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 equipment,

follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.

PRESSURIZED ALUMINUM PARTS HAZARD

Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical
reaction and equipment rupture, and result in death, serious injury, and property damage.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

• Gloves

• Hearing protection

312054J 3

Installation

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ti9448a

0.25

11/32 thru or tap 5/16-18 thru

(0.6)

Measurements shown in
Inch (cm)

4 Places

Solenoid Only

Solenoid Installed

B

A

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ti12241a

C

Installation

Fill all lube points with grease before removing zerk fit­tings to change to tube connector fittings. This ensures
each lube point will readily accept grease.

Pump Mounting

NOTE:

• Pump mounting is the same for either an air or
electric pump.

• When using an electric pump omit Solenoid
Installation and Timer Installation.

• Mounting holes and dimensions are the same
on both styles of pump (See F

• A pump mounting bracket is available. Contact
your Graco distributor.

The pump inlet is gravity fed, therefore the pump must
be set vertically.

Select a location that is:

• visible

• accessible for filling the reservoir

• protected

IG. 1).

Air Operated Pump

Solenoid Installation

Be sure you have the correct voltage to match your
vehicle's electrical system.

1. Apply thread sealant to fitting threads (A).

2. Thread fitting (A), to the bottom of the pump. Hand
tighten only.

3. Use an open end wrench to tighten fitting. Side port
of fitting must point toward rear of vehicle.

4. Apply thread sealant to solenoid threads (B).

5. Thread solenoid (B) to the side port on fitting (A).
Wrench tighten.

6. Apply thread sealant to plug threads (C).

7. Thread plug (C), to the bottom of fitting (A). Wrench
tighten.

8. Reconnect air line.

9. Attach electric connector.

The completed installation should look like F

IG. 2.

A 22-ft (6.7 m) harness wire kit to supply the signal from
the timer is available (Parts, page 19). This harness
comes with a weather tight connector to mate with the
solenoid connector (F

IG. 2).

IG. 1

F

4 312054J

FIG. 2

Installation

Pump

Solenoid

Timer

User Supplied

Red

Orange
+12 Battery

+Ignition

Black
Ground

ti11880a

Timer

Solenvoid Valve

YELLOW

BLUE

WHITE

BLACK

Black (-)
Ground

Red (-)
(ignition on)
from keyswitch

Orange(+)
battery terminal
(memory)

5-amp
fuse

5-amp
fuse

Load wires
blue and
yellow

12 to 32 VDC

Timer Installation

1. Install timer horizontally in a protected, but easily
accessible location, inside the truck cab using the 4
mounting screws provided (F

2. Connect timer leads to solenoid. A wiring harness
kit with a mating connector is available from your
Graco distributor. Order Kit 557929.

NOTE: All connections between timer and solenoid
must be moisture-proof and safe from grounding.

3. Connect the yellow timer lead to the red wire from
the solenoid (F

IG. 3.).

IG. 3).

NOTICE

Do not ground the yellow wires to the solenoid. This
could cause damage to the timer.

4. Connect the red lead wire to the positive side of the
vehicle ignition switch. Install a 5 amp fuse at this
connection.

5. Connect the orange lead wire to the battery positive
terminal circuit. Install a 5 amp fuse at this connec­tion.

6. Connect the black lead wire to the chassis ground.

FIG. 3

312054J 5

Installation

ti9497

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Electric Pump Installation

NOTE: Electric Grease Jockey pumps are available with
or without a timer. Choose the appropriate installation
section.

Fuses

The following fuse information applies to all models:

• Use standard automotive style blade fuses, ATO
series 257. Fuses are available from your Graco
distributor.

• Never use a higher amperage capacity fuse. Dam­age to the pump and vehicle electrical system could
occur.

• Install fuse holders in a protected area, as far from
the pump as possible. This will provide maximum
protection to the vehicle electrical system.

Pump Models without a Timer

Refer to Wiring Schematic (FIG. 4) for these instructions.

1. Install 10 Amp fuse (12 VDC models) or 5 Amp fuse
(24 VDC model) in line with the White wire con­nected to the first pole of the Hirschmann connector.

2. Wire as follows. If using a Graco mating cable, the
wire color corresponding to the 3-Pole Hirschmann
connection point is provided in parenthesis.

NOTE: The Hirschmann connection labeled ground, or
the green wire of a Graco mating cable, is not used for
either voltage models.

Pump Models with a Timer

Refer to Wiring Schematic (FIG. 5) for these instructions.

1. Install 10 Amp fuse (12 VDC model) or 5 Amp fuse
(24 VDC model) in line with the wire connected to
the third pole of the Hirschmann connector.

2. Install a 5 Amp fuse in line with the wire connected
to the first pole of the Hirschmann connector
(applies to both 12 and 24 VDC models).

3. Wire as follows. If using a Graco mating cable, the
wire color corresponding to the 4-Pole Hirschmann
connection point is provided in parenthesis.

• Chassis Ground (-) to Hirschmann connection,

labeled number 2 (Black wire)

• Battery (+) to Hirschmann connection, labeled

number 1 (White wire) - This source should
always provide a voltage supply.

• Ignition (+) to Hirschmann connection, labeled

number 3 (Red wire) - This source should only
provide a voltage supply when the vehicle igni­tion switch is on.

• Chassis Ground (-) to Hirschmann connection,
labeled number 2 (Black wire)

• Ignition (+) to Hirschmann connection, labeled
number 1 (White wire) - This source should only
provide a voltage supply when the vehicle igni­tion switch is on.

FIG. 5

F

IG. 4

6 312054J

Modules

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A

&RONT

&RONTSPRING
PINMETER

$USTCOVER
MOUNTINGBRACKET
ANDCLAMP

$RAG
LINK

4IEROD

!LLOWSLACKFORDRAG
LINKMOVEMENT

3PRINGSHACKLES

TUBEBUNDLE

,EFTFRONTMETERBLOCKASSEMBLY
LOCATEDASNEARTOAXLEASPOSSIBLE

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Upper and Lower
King Pin

F

IG. 6

Installation

• Modules (Fig. 6) are mounted with a ported stud (A)
through a 5/8 in. (16 mm) hole.

• Mount all modules on the frame rail or a cross mem­ber close to the points they will be lubricating.

• Grease Jockey kits come with module assemblies
for each strategic area of the chassis to be lubri­cated: Left Front (F
Axle(s) (F

• The unused ports in the manifolds should have
plugs in them. If additional lube points are needed
these plugs can be replaced with appropriate sized
meters and lines.

IG. 9) and Fifth Wheel (FIG. 10).

IG. 7), Right Front (FIG. 8), Rear

Left Front Module (FIG. 7)

The Left Front Module assembly contains meters, hardware and tubing for:

• 2 king pins,

• 1 spring pin,

• 2 spring shackle pins,

• 1 tie rod,

• 2 drag links,

• 1 S-cam,

• 1 slack adjuster lube points.

• Optional points from this module typically are

linkage and steering box points.

FIG. 7

312054J 7

Installation

TO TRANSMISSION CROSS
SHAFT LUBE POINTS

TWO

-TUBE BUNDLE

FRONT SPRING
PIN METER

FRONT

ALLOW

AMPLE SLACK FOR TIE

RODMOVEMENT

THREE

-TUBE BUNDLE

ALLOW SLACK FOR
WHEEL MOVEMENT

ti9455

UPPER AND LOWER
KING PIN

Right Front Module (FIG. 8)

The Right Front Module assembly contains meters, hardware and tubing for:

• 2 king pins,

• 1 spring pins,

• 2 spring shackles,

• 1 tie rod,

• 2 clutch cross shafts,

• 1 S-cam, and 1 slack adjuster lube points.

• Optional points from this module typically may be body pivot pins.

F

IG. 8

8 312054J