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
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
ti11846b
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
ti9496
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
ti9452a
A
&RONT
&RONTSPRING
PINMETER
$USTCOVER
MOUNTINGBRACKET
ANDCLAMP
$RAG
LINK
4IEROD
!LLOWSLACKFORDRAG
LINKMOVEMENT
3PRINGSHACKLES
TUBEBUNDLE
,EFTFRONTMETERBLOCKASSEMBLY
LOCATEDASNEARTOAXLEASPOSSIBLE
ti9454
tti9454
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
Rear Axle(s) (FIG. 9)
!LLOWSLACKFORAXLEMOVEMENT
INTUBING
MAINLINE
&RONT
-ODULE!SSEMBLY
2EARAXLEMETERBLOCKASSEMBLY
LOCATEASNEARTOAXLEASPOSSIBLE
"RAKESHAFT
3LACKADJUSTER
3ECUREALLLINESWITHNYLON
STRAPSTOAVOIDTUBINGABRASION
4WOTUBE
BUNDLES
ti9456
This assembly contains the meters, hardware, and tubing for:
Installation
• (2 or 4) S-cams
• (2 or 4) slack adjuster lube points. The number
of points is determined by the application (single
or tandem axle).
• Optional points for this module may be spring
pin points or trailer system meters.
F
IG. 9
312054J 9
Installation
INTUBING
0LATE
INTUBING
0IVOT
-ODULE
ASSEMBLY
INTUBING
TRUNKLINE
4WOINTUBEBUNDLES
!LLOWSLACKFORTHWHEELMOVEMENT
3ECUREALLLINESWITHNYLON
STRAPSTOAVOIDTUBINGABRASION
&RAMERAIL
ti9457
Fifth Wheel (FIG. 10)
This assembly contains the meters, hardware, and tubing for:
• 4 face plates
• 2 pivot pin lube points.
NOTE: Most 5th wheel plates do not have grease fittings in the plate. This requires four holes to be drilled and
tapped (1/8 in. npt) through the plate. These meters should be #8.
F
IG. 10
10 312054J
Installation
Tubing
NOTICE
• When installing the tubing avoid routing it close to a
heat source such as an exhaust manifold, muffler,
turbocharger, etc.
• Non-approved nylon or air brake tubing should not
be used.
• Always use approved 3/16 in. (5 mm) and 5/16 in.
(8 mm) OD tubing.
The 3/16 in. (5 mm) tubing comes in three configurations.
• Single tubes: black or orange,
• 2 tube bundles: black with an orange tube
inside sheath.
• 3 tube bundle: black, blue and orange tube
inside a sheath.
• The orange tube is connected to the highest
output meter.
• The blue tube is connected to a lesser or
equal output meter.
Installation
A self aligned ferrule is supplied with all 3/16 in. and
5/16 in. fittings. It is not necessary to remove the nut and
ferrule to seat the tube into the fitting.
1. Make sure the tube is well seated into each fitting.
Brass inserts are supplied with kits for use with 5/16
in. tubing. These inserts must be used at every 5/16
in. connection.
2. Route the 5/16 in. main line tube from the pump to
the manifolds.
NOTE: The 5/16 in. main line tube may also be used as
the air supply line to the solenoid. It should be routed
inside the frame for protection and well secured.
Filling System and Start Up
NOTICE
• The Grease Jockey system is designed to pump
lightweight fluid greases and oil over a wide range
of conditions.
• Choose a lubricant compatible with the system’s
operating temperature.
• The black tube is connected to the lowest or
equal output meter of the bundle group.
Preparation
1. Measure approximate lengths of tube bundles, leaving extra length for trimming at the lube points.
2. Cut the outside sheath on tube bundles back to the
point where this bundle meets it’s first lube point. Be
careful not to puncture or cut the tubes inside.
Use a stripper to help prevent damage to the tubes.
3. Peel back the outside sheath onto itself to create a
collar and cut off the excess. Be careful not to
sever the remaining sheath or tubes.
4. Align tubing with fitting. Make cuts square and clean
with an anvil type cutter.
5. Allow ample slack for tube movement and ease of
installation.
• Use lubricant part number 557941, or a quality
NLGI “0” or “00” lithium base grease with an “EP”
additive.
• Systems using fluid grease:
• MUST use NGLI grade “00” grease at tempera-
tures below 50°F (10 °C).
• MAY use NGLI grade “0” or “0” at temperatures
above 50°F (10 °C).
312054J 11
Installation
ti11499
Reservoir Bag
Stiffener
Clamp
ti11495
Depress bag
inside stiffener
to purge air
from bag
Reservoir Bag Installation (FIG. 11)
F
IG. 11
1. Lightly coat inside of reservoir bag with grease.
2. Insert stiffener inside bag, approximately 1/2-inch
(1.27 cm) up from bottom.
3. Position bottom of bag over flange on pump body.
Be sure stiffener is seated in pump body.
4. Place clamp over bag and position loosely around
bottom of bag.
5. Depress top of bag inside stiffener to purge air from
bag. Fully depressed bag will contact pump casting.
Flexible Reservoir Fill and Refill
1. Fill reservoir through fill stud. Pump output port
should be connected to system or plugged to avoid
spillage.
2. Fill reservoir bag until bag takes its original shape
(top of bag slightly domed). Do not overfill.
Rigid Reservoir Fill and Refill
1. Fill reservoir through fill stud. Pump output port
should be connected to system or plugged to avoid
spillage.
2. Fill reservoir to full line. Do not overfill.
Reducing Grease in Reservoir When Overfilled
Follow this procedure to reduce the grease in the reservoir if the pump is accidentally overfilled.
1. Disconnect the main line from the pump or at the
first module.
2. Cycle pump with the timer on “test” for a few minutes until the level of grease is acceptable. Be sure
to capture grease.
3. In rigid reservoir, clean breather tube of residual
grease.
4. Return timer to original setting and reconnect main
line.
Pump Filter
The pump assembly contains a filter to remove impurities and dirt that may be present in the lubricant used to
fill the reservoir.
Clean filter after every four or five reservoir refills. To
clean the filter:
1. Remove the quick fill fluid fitting.
2. Remove the filter and clean with solvent or compressed air as appropriate.
3. Replace filter in pump body, flanged end facing out.
4. Reassemble the quick fill fluid fitting.
F
IG. 12
A mating female quick disconnect is available. Contact
your Graco distributor. Order part number 557877.
6. Tighten clamp after air is purged out of reservoir
bag.
12 312054J
Adjusting Grease Output Volume
Installation
If a meter is not producing the correct amount of lubricant for a specific location on a vehicle or if a replacement meter of correct size is not available, output
spacer washers can be installed to adjust the meter’s
output volume.
TABLE 1: Meter Identification and Usage
Meter
Size
0
1
2
3
4
8*
Number of
Washers
0 No 0.002 Brake Shafts, transmissions, cross shafts, “S” cams
1 No 0.005 Slack adjusters, 5th wheel pivot, and miscellaneous points
2 No 0.009 Drag link, tie rod ends, power steering linkage
3 No 0.012 Kin pins, spring pins, spring shackles
4 No 0.020 Misceallenous points
4 Yes 0.026 5th Wheel plate
*Size 8 high output meters cannot
Hex
Flat
be changed.
Output
3
(in.
)
Use Table 1 to determine which size meter is appropriate for the grease location.
Recommendations for
Specific Lubrication Points
To change output volume:
1. Relieve pressure, page 15.
2. If the meter is located on a manifold, use a 7/16”
wrench to remove tubing (F
IG. 13).
FIG. 13
3. Use a 5/8” deep well socket to remove meter from
manifold (F
IG. 14).
FIG. 14
4. Place meter in a vise, output end (tube connector)
facing up.
5. Use two 5/8” wrenches to separate the meter
halves.
6. Separate the meter body from the valve assembly.
Be careful not to misplace or damage springs and/or
312054J 13
Installation
A
o-rings that may be attached (FIG. 15).
force to seat output washers firmly (F
IG. 16).
FIG. 16
9. Align hex flats so a deep well socket will slide down
to the meter body for assembly onto manifold.
10. Reassemble meter onto manifold using the 5/8”
deep well socket. Torque to 2-3 ft.-lbs.
NOTICE
Do not xceed 12 ft-lbs torque or meter damage may
occur.
F
IG. 15
7. Add or remove output spacer washers (A) from the
meter valve assembly.
NOTE:
• Add spacer washers (A) to increas output vol-
ume.
• Remove spacer washers (A) to decrease output
volume.
8. Reassemble meter body on meter valve assembly.
Use a 5/8” wrench to tighten using only enough
11. Hand tighten the tube nut onto the meter and tighter
1/8 turn beyond hand tight.
NOTE: Tube nuts can be reused a maximum of 8
times after the initial tightening.
12. Reconnect tubing to manifold using a 7/16” wrench
to securely tighten fitting.
14 312054J
Installation
Bottom Cover O-Ring
This section applies to Electrically Operated Grease
Jockey Systems only. For Air Operated Grease
Jockey System installations, skip this section and go
right to Purging Air from the Main Line, page 15.
An o-ring for sealing between the bottom cover and
pump body was shipped loose with the pump. This
o-ring must be installed prior to assembling the bottom
cover to the pump.
1. Gently stretch the o-ring to enlarge it slightly.
2. Coat the o-ring with a light film of grease or oil.
3. Insert the o-ring into the groove in the pump body.
4. If using a pump with a timer, adjust the timer settings:
a.
• The knob on the left controls cycle off time,
• The knob on the right controls cycle on time.
b.
• Turning knob clockwise increases current
cycle setting.
• Turning knob counter-clockwise decreases
the current cycle setting.
c.
• Off time is continuously adjustable from 10-45
minutes.
• On time is continuously adjustable from 30-90
seconds.
5. Coat the top lip of the cover with a light film of
grease or oil.
6. Assemble the cover to the pump body.
7. Approximately 3/8 in. (10 mm) of the tie rod will be
visible when the cover is seated correctly.
8. Place the washer and nut onto the portion of the
threads exposed and tighten securely.
Pressure Relief
Purging Air from the Main Line
NOTE:
• Check the vehicle air supply. At least 100 psi
(0.7 MPA, 7 bar) gauge pressure is required.
• All the air must be removed from the main lines
and manifolds.
1. Remove all 1/4 npt end port and 1/8 npt stud plugs
on the module manifolds.
2. With the vehicle ignition switch turned ON, set timer
to the test position and press MANUAL RUN.
3. As the pump cycles, check the open module ports
for flow of grease with no air.
4. Check the open port closest to the pump first, proceeding to the port furthermost from the pump last.
This will push out the air in the main line(s).
5. When the flow of grease from a port is free of air,
close the port and continue this process until all
ports have been checked.
NOTE: The 3/16 in. (5 mm) distribution lines are
pre-filled. They should not require purging of air.
6. Let the system run in the test position for a few minutes. Check all line connections to be sure they are
holding pressure. Check at lube points to be sure
lubricant is moving to this point in the system.
7. Reset the timer to the desired setting for your application. Use the following table as a starting point:
Recommended Timer Setting
Timer Setting Driving Conditions
1/2 or 1 hr Off Highway
Start and stop city, heavy salt,
1.5 or 2 hr
3 hr
NOTE: These are recommended settings only. Experience with individual applications will determine timer
setting.
snow and ice, rough pavement,
wet climate, heavy loads, dusty
roads.
Normal city or highway driving,
normal climate, moderate loads.
If any part of the system has not functioned as it should,
refer to Troubleshooting, page 16.
312054J 15
Troubleshooting
Troubleshooting
Problem Cause Solution
Too much grease at all lube points Timer cycle too frequent Adjust the timer one click to a higher time
cycle. (Example, from 2 to 3 hours.)
Too much grease at one lube point Meter leaking Remove and replace meter
Not enough grease at all lube
points
No sign of fresh grease at all points Lubricant reservoir filled with
Timer cycle is too infrequent Adjust the timer one click to a lower time
cycle. (Example, from 3 to 2 hours.)
Remove and clean reservoir, refill with
heavy grease which will not
work in system.
Blown fuse, or break in wiring
circuit
Broken air line (air pump only) Repair or replace line.
Inoperative solenoid air valve
(Air pump only)
Inoperative air pump
Inoperative electric pump See Troubleshooting, Electrically operated
proper lubricant. Remove main line plugs
from meter blocks, and cycle pump until old
lubricant is removed from lines, replace
main line plugs.
Check for electrical short circuit or broken
wire, and repair.
Check electrical circuit to make sure volt-
age is reaching the solenoid coil from the
timer. Connect a meter from the supply
“black” wire to the return “white” wire at the
connector of the solenoid. Do not connect
direct to ground. Repair or replace wiring
as required: Check coil resistance for
approx. 20 ohms. Check valve operation;
repair or replace if necessary.
See Troubleshooting, Air-operated pump
not working, page 18.
pump not working, page 18.
16 312054J
Troubleshooting
Problem Cause Solution
(cont.) Inoperative timer With the ignition switch on, check the input
voltage of both the memory (orange) and
the (red) switch wires; if there is not 12
VDC (or greater) repair electric supply. Set
the timer to TEST. Check the output signal
to the solenoid. Connect a meter from the
timer supply to the return. Not to a ground.
(At the timer connector the supply is the
blue wire and yellow is the return), (At the
solenoid connector the supply may be a
black wire and return a white wire). It
should show 12 VDC during the ON cycle
(approx. 45 sec.) and 2 VDC or less during
the OFF period (approx. 45 sec.) If there is
no signal or a constant 12 VDC output,
check lines from the timer to the solenoid
for grounding or breakage; replace timer if
necessary.
Main line broken See Troubleshooting, Main tube line dam-
aged, page 17.
None of the above Using 2500 PSI pressure gauge, check for
pressure at last module in system. The
minimum gauge reading should be 500
PSI. If not, check pressure at pump. Pressure should reach 1000PSI. If it does,
check for blocked, broken or collapsed
main line. Otherwise repair or replace
pump.
No sign of fresh grease at some
lube points
Main line broken See Troubleshooting, Main tube line dam-
aged, page 17.
Air lock in main line Purging Air From the Mainline; Step 7,
page 15.
No sign of fresh grease at one lube
point
Secondary line damaged See Troubleshooting, Secondary line dam-
aged, page 17.
Meter inoperative Replace meter.
Lube point fitting has broken off Remove broken fitting and replace
Main tube line damaged Trapped and broken, rubbed
through
Replace or repair (re-route or protect the
line to prevent the damage from happening
again). Purge with grease to expel air
before connecting new main line into system. Be sure to use a tube insert at all main
line connections.
Main line has popped out of fitting
Secondary line damaged Trapped and broken, rubbed
through
Refit line to the fitting using a new compression sleeve and a tube insert.
Replace or repair (re-route or protect the
line to prevent the damage from happening
again).
Secondary line has popped out
of fitting
Refit line to the fitting using a new compression sleeve.
Lube point fitting has broken off Remove broken fitting and replace.
312054J 17
Troubleshooting
Problem Cause Solution
Air-operated pump not working Solenoid valve not working See Troubleshooting, No sign of fresh
grease at all points “Inoperative solenoid
air valve”, page 16.
Air line damaged Repair or replace if necessary.
Low air pressure Build up air pressure in truck system.
Electrical circuit to timer or
solenoid is damaged
Check connections; repair or replace if nec-
essary.
Timer is not working Repair or replace timer.
Electrically operated pump not
working
Electrical circuit is damaged Check electrical circuit to make sure volt-
age is reaching motor.
Inoperative motor Repair or replace motor if necessary.
18 312054J
Rebuilding Grease Jockey Pump
6
7
8
9
10
2
1
5
3
ti11523
1
14
16
15
4
1
Ref. Description Qty.
1 SCREW, 3/8” x 3/4” 6
2 WASHER, flat, 3/8” 6
3 O-RING, fluoroelastomer A, 70
DURO, 1/16”
4 O-RING, fluoroelastomer A, 70
DURO, 1/8”
5 GASKET, pump 1
6 SPRING, check valve 1
7 SPRING, return, piston 1
8 PISTON, lube 1
9 DIAPHRAGM
10 COVER, chamber
14 BODY, pump
15 FITTING, coupling 3/8” x 1/4”
16 PISTON, check valve
* For reference only. Not included in kit.
Rebuilding Grease Jockey Pump
1
1
1
1
*
*
*
F
IG. 17
Use Pump Rebuild Kit 563762. Numbers in parentheses
refer to F
IG. 17.
Piston Chamber Repair
1. Remove the grease mainlines from the pump.
2. Relieve Pressure, page 15. Remove air supply line
and electrical connector from solenoid valve.
3. Remove pump from vehicle.
It may be necessary to empty reservoir of grease for
remaining steps.
4. Turn pump upside down to remove bottom air
chamber cover screws.
Torque to 15-22 ft.-lbs (20-30 N.m) and
apply Loctite
®
242
5. Using a 9/16” wrench, remove solenoid valve from
cover (10) by unscrewing the brass nipple from the
pump body.
6. Using a 9/16” wrench, remove six hex screws (1)
and washers (2) from cover. Use care in removing
the last screw since the internal components are
under compression and the cover will pop off. Discard all screws and washers.
7. Remove the diaphragm (9) and any fragments of
the gasket (5) and discard.
8. Remove the piston (8) and spring (7) from the pump
cavity. Discard both the piston and spring.
9. Remove o-ring (4) from top of piston and discard.
10. Clean excess grease, grit and dirt from the inside of
the pump with a clean paper or cloth towel. Check
312054J 19
Rebuilding Grease Jockey Pump
piston cavity for scoring or scrapes. Clean piston.
Make sure there are no fibers from cloth left behind.
11. Check to make sure flapper valve is visible and
loose in top of piston cavity. If flapper is not visible
or frozen in place, the pump cannot be repaired.
Replacement part number is 563625.
12. Assemble new o-ring and new spring to the new piston and insert in pump. To aid in reinsertion, apply a
small amount of grease to the o-ring.
13. Position new diaphragm on piston. Make sure orientation is according to F
14. Position new gasket and cap back onto pump and
screw into place. Replace o-ring and hex screws.
Torque to 15-22 ft.-lbs. Alternate tightening screws
around cover to avoid excessive tilting of cover.
IG. 17.
Check Valve Repair
1. Using a 3/4” wrench, remove fill stud fitting (15)
from pump body.
2. Using a 5/16” wrench, remove check valve spring
(6), o-ring (3) and check valve piston (16). Discard
spring and o-ring.
5. After vehicle air pressures has reached a minimum
of 100 psi (6.89 bar, 0.689 MPa):
• turn ignition to ON
• Timer to TEST position
• push the MANUAL RUN button
Watch the pump outlet for grease flow.
6. Once grease flows from the outlet:
• stop the cycling
• return the timer to the original setting
• reconnect the mainline to the pump
NOTE: Any tube nut can be removed and reconnected
up to 8 times. to reattach, hand tighten up to original
make-up position plus 1/16 turn to seat ferrule.
7. Pump can now be returned to service.
3. Clean cavity with clean paper or cloth towel. Make
sure no fibers are left in the cavity.
4. Replace o-ring (3) and reinstall check valve piston in
cavity. Make sure piston is properly oriented in cavity -- o-ring on the outside end.
5. Install new check valve spring (6) in cavity.
6. Apply pipe dope to fitting (15) and reinstall.
Assembling Pump Onto Vehicle
1. Assemble pump onto vehicle.
2. Connect solenoid air supply line to the side port of
the solenoid.
3. Reconnect solenoid electrical harness.
4. If reservoir was emptied, refill with appropriate
grease.
20 312054J
Parts
ti9460
ti9461
ti9462
ti9463
ti9464
ti9466
ti9467
ti9468
Installation kit:
Description Part Number
30 pt single axle tractor, air pump,
and flexible reservoir
34 pt tandem axle tractor, air
pump, and flexible reservoir
30 pt single axle tractor, electric
drive pump, flexible reservoir
Air pump repair/rebuild kit 563762
Soft to hard conversion kit 563931
Manual Trailer kits:
6 pt single axle system 563805
12 pt tandem axle system 563806
5 pt landing gear system 563807
FILLER PUMP ASSEMBLY
Fits 35 lb pail
563569
563801
563802
563804
Parts
AIR PUMP ASSY.
W/6 LB RIGID RESER.
563584
6LB RESERVOIR
REPLACEMENT KIT
563774
TIMER FOR AIR SYSTEM
(12-32) VDC
557926
ELECTRICAL WIRE LEAD
FOR AIR PUMP TIMER
557929
35 LB. PAIL GREASE
NLGI “00”
Non-Moly
557941
AIR PUMP ASSY.
W/FLEX RESER.
563570
FLEXIBLE RESERVOIR
REPLACEMENT KIT
563761
RESERVOIR ONLY
557884
CLAMP
557878
SOLENOID VALVE KIT
12 VDC - 557932
24 VDC - 24E017
WIRE LEAD - 22 FT.
FOR SOLENOID VALVE
563642
METER VALVES
#0 = 563627
#1 = 563629
#2 = 563631
#3 = 563633
#4 = 563635
#8 = 563637
METER OUTPUT
PORT PLUG
557901
METER OUTPUT
SIZING SPACER
557898
312054J 21
Parts
ti9469
ti9470
ti9471
ti9472
ti9473
ti9474
ti9475
ti9476
ti9477
ti9478
ti9479
ti9480
ti9481
12 PORT MANIFOLD
WITH STUD
563758
REPLACEMENT STUD
563946
MANIFOLD METER
PORT PLUG
15M038
TUBE STRIPPER
558058
DISTRIBUTION LINES
3/16” OD TUBING
BUNDLES PREFILLED
563786 = 1 TUBE BLACK
563788 = 2 TUBE BUNDLE
563783 = 3 TUBE BUNDLE
MAIN LINE TUBING
5/16” OD X 60 FT.
561132
CLAMPS 9/32” HOLE
5/16” - 557943
3/8” - 557946
7/16” - 557944
1/2” - 557947
5/8” - 557945
NUT, TUBE WITH
CAPTIVE SLEEVE
3/16” TUBE - 556660
5/16” TUBE - 556666
MALE CONNECTOR
1/8” NPT
3/16” TUBE - 556644
5/16” TUBE - 556645
1/4” NPT
5/16” TUBE - 556646
MALE 90° ELBOW
1/8 NPT
3/16” TUBE - 556638
5/16” TUBE - 556639
1/4” NPT
5/16” TUBE - 556640
5/16” TUBING INSERT
PACKAGE OF 20
557963
FITTING ADAPTER STRAIGHT
1/4”-28 SAE X 3/16” TUBE
562995
NYLON STRAPS
PACKAGES OF 100
563770
ELBOW, STREET
1/8” NPT TO 1/4” - 28 SAE
STANDARD - 15K740
SHORT - 15K784
22 312054J
Parts
ti9482
ti9483
ti9484
ti9485
ti9486
ti9487
ti9488
ti9489
ti9490
ti9491
ti9492
ti9493
ti9494
ti9495
ELBOW STREET
1/8” NPT TO 1/8” NPT
90° - 15K783
45° - 557395
3/8” NPT TO 3/8” NPT
90° - 560534
ADAPTER, STRAIGHT
1/8” NPT TO 1/4” - 28 SAE
MALE
557955
ADAPTER, PRESS TO FIT TO
REPLACE UNTHREADED
GREASE FITTINGS, 1/8” NPT
15M037
TUBE UNION
3/16” TUBE - 556647
5/16” TUBE - 556648
ZERK ADAPTER
PRESS-ON
3/16” TUBE CONNECTION
ELBOW - 563776
ZERK ADAPTER
PRESS-ON
3/16” TUBE CONNECTION
STRAIGHT - 563777
ELECTRIC PUMP
ASSY, FLEX. RESERVOIR
WITH TIMER FOR:
12 VDC - 563595
24 VDC - 563596
TEE MALE BRANCH
1/8” NPT TO 5/16” TUBE
556636
TEE, TUBE UNION
5/16” TUBE - 556637
BULKHEAD FITTING
557950
EXTENSION, 1/8” NPT
3/4” - 557392
1 1/4” - 557393
UNIVERSAL PUMP
MOUNTING BRACKET
557966
RESERVOIR FILL
COUPLING FEMALE
1/4” NPT FEMALE
557877
RESERVOIR FILL
COUPLING MALE
3/8” NPT MALE
557880
DUST CAP
557875
SERVICE START-UP KIT
563775
CONTAINS SOLENOID,
TUBES, FITTINGS, INSERTS,
AND PUMP REPAIR KIT
312054J 23
Technical Data
Technical Data
Timer (Air Operated Pump)
Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 -24 VDC
Timer Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5, 1, 1.5, 2, 3, 4, 6 hours
Wire Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . Packard Connector
Air Solenoid
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-Way, Normally-Closed, Free Venting
Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 or 24 VDC, 9 Watt Continuous Duty Coil
Inlet Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/8 npt threads
Outlet Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 npt threads
Maximum Working Pressure . . . . . . . . . . . . . . . . . . . 150 psi (1.05 MPa, 10.5 bar)
Air Operated Pump
Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9:1
Output per Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet Pressure (air) . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 - 150 psi (0.28 - 0.35 MPa, 2.8 - 3.5 bar)
Outlet Pressure (lubricant). . . . . . . . . . . . . . . . . . . . . 360 - 1350 psi (2.5 - 9.4 MPa, 25.2 - 94.5 bar)
Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . -4 to 135°F (-20 to 57.2 °C)
Fluid Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil and Grease, NLGI #0 or lighter
Electrically Operated Pump
Fluid Outlet Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 1,000 psi (7.0 MPa, 70 bar)
Pump Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil (all temperatures)
Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 or 24 VDC, 5 Amps
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum 30% (cycle on time not to exceed 2 minutes)
Modules (includes tubing, manifolds and meters)
Manifold
Maximum Working Pressure . . . . . . . . . . . . . . . . . . . 2,500 psi (17.5 MPa, 175 bar)
Meters
Maximum Working Pressure . . . . . . . . . . . . . . . . . . . 2,000 psi (13.7 MPa, 137 bar)
Minimum Operating Pressure . . . . . . . . . . . . . . . . . . 450 psi (3.2 MPa, 31.5 bar)
Vent Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 psi (1.1 MPa, 11.2 bar)
Minimum Cycle On Time . . . . . . . . . . . . . . . . . . . . . . 30 seconds
Minimum Cycle Off Time . . . . . . . . . . . . . . . . . . . . . . 3 minutes
Tubing
5/16” OD Main Line Maximum Working Pressure . . . 375 psi (2.6 MPa, 25.8 bar)
3/16” OD Distribution Line Maximum Working Pres-
sure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
1.5 in
2.0 in
NLGI #0 grease at 50°F (10 °C) or higher
NLGI #00 grease for at 50°F (10 °C) or lower
800 psi (5.5 MPa, 55 bar)
(24.58 cc)
3
(32.77 cc) per minute
24 312054J
Notes
Notes
312054J 25
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.
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 2008, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Graco reserves the right to make changes at any time without notice.
For patent information, see www.graco.com/patents.
Original instructions. This manual contains English. MM 312054
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
www.graco.com
Revised May 2014
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