Graco 24W482 User manual

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.

Warnings

2334662B

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-

tion 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 com-

ponent. 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 manu-

facturer’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.

WARNINGWARNINGWARNING

WARNING

Component Identification

334662B 3

Component Identification

Keypad, Display, and Icons

Pump ON LEDs (A)

• Time Control LED: In RUN MODE illuminates

indicating function mode that is currently run-

ning.

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 con-

troller is in SETUP MODE.

• In RUN MODE numbers on the display will not

blink.

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 com-

plete ON cycle if actuated during the OFF por-

tion 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.

• Press and hold left and right direction arrow

together for 3 seconds to enter TEST MODE.

NOTICE

To prevent damage to soft key buttons, do not press

the buttons with sharp objects such as pens, plastic

cards, or fingernails.

FIG. 1

Installation

4334662B

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

Pump

Solenoid

Timer

Fuse (user supplied)

Red

+Ignition

Black

Ground

Wiring

Harness

Mating Harness

Installation

334662B 5

System Wiring

Timer Installation

1. Connect timer leads to solenoid. A wiring harness

kit with a mating connector is available from your

Graco distributor.

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.

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.

Installing the Lubrication

Controller

1. Select a flat surface to install the Lubrication Con-

troller. 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 (FIG. 4, (a).

Use two screws (not provided) to secure junction

box to mounting surface.

AUTOMATIC SYSTEM ACTIVATION HAZARD

Unexpected activation of the system could result in seri-

ous 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.

NOTICE

Do not ground the yellow wires to the solenoid. This

could cause damage to the timer.

FIG. 3

FIG. 4

Setting Up a Personal Identification Number (PIN) (Optional)

6334662B

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 sec-

onds.

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 num-

bers 0-9 until the first number

in the PIN code is displayed in the 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.

Entering Advanced Setup

Press the UP ARROW button for 3 sec-

onds.

If the Grease Jockey Controller was previ-

ously set up to require a PIN Code:

1. Use the UP and DOWN

ARROW buttons to move up

and down through the num-

bers 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.

Setup

334662B 7

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 auto-

matically 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.

• 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

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.

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.

Setup

8334662B

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 Illu-

minates.

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.

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 pro-

gram 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.

• 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.

Setup

334662B 9

Operation

Run Mode

The controller is in Run Mode providing the following cir-

cumstances 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:sec-

onds).

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).

• 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.

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.

Troubleshooting

10 334662B

Troubleshooting

Program Settings Recommended Timer Settings

NOTE: These are recommended settings only. Experi-

ence with individual applications will determine timer

setting.

Description Problem Solution

Unit does not power on or display is

dim/unresponsive

Incorrect or loose wiring Refer to installation instructions

beginning on page 4.

Input voltage is out of range Confirm power source is between 9

and 30 VDC.

Tripped external fuse Confirm that none of the devices or

wiring connected to the controller are

causing a short circuit connection.

Replace fuse. If fuse trips again, con-

tact Graco Customer Support.

Pump is not running during Pump ON

Incorrect or loose wiring Confirm current is being delivered to

the pump during pump ON. Refer to

installation instructions, page 4. Ver-

ify that your machine has been wired

correctly.

Controller output is incorrect Confirm output voltage (PUMP+)

from controller during pump ON is

correct (should be similar to input

voltage).

NOTE: Measure at controller to

ensure there is not wiring issue caus-

ing the problem.

If controller output voltage is never

present, the device may need

replacement.

Air solenoid failure Replace air solenoid.

Reservoir quickly and unexpectedly

runs out of grease

Test mode is engaged Turn off test mode.

Description

Modes of Operation

Maximum / Minimum

TIME ON, page 7 MM:SS (00:01 - 59:59)

TIME OFF, page 8 HH:MM (00:01 - 99:59) Timer Setting Driving Conditions

1/2 or 1 hr Off Highway

1.5 or 2 hr

Start and stop city, heavy salt, snow

and ice, rough pavement, wet climate,

heavy loads, dusty roads.

3 hr Normal city or highway driving, normal

climate, moderate loads.

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