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.
EN

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
F
B
A
C
E
D

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
a
a

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.