Graco 24Z764 Instructions Manual
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Graco 24Z764 Instructions Manual

Electric grease jockey automatic lubrication system
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Instructions
Electric Grease Jockey
Automatic Lubrication
System
For dispensing of NLGI Grades #000 to #2 greases. For Professional Use Only.
Not approved for use in explosive atmospheres or hazardous locations.
2000 psi (13.79 MPa, 137.9 bar) 24Z764, 24Z959, 24Z660, 24Z958, 26C494
1000psi (6.89 MPa, 68.9 bar) 26C495, 26A848
Important Safety Instructions
Read all warnings and instructions in this
manual. Save all instructions.
3A5082G
EN

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Summary of Contents for Graco 24Z764

  • Page 1 For dispensing of NLGI Grades #000 to #2 greases. For Professional Use Only. Not approved for use in explosive atmospheres or hazardous locations. 2000 psi (13.79 MPa, 137.9 bar) 24Z764, 24Z959, 24Z660, 24Z958, 26C494 1000psi (6.89 MPa, 68.9 bar) 26C495, 26A848...

  • Page 2: Table Of Contents

    Injectors ....... . . 44 Parts: 24Z660, 24Z958, 24Z764, 24Z959, Parts .

  • Page 3: Warnings

    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 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.
  • Page 4 Warnings WARNING PLASTIC PARTS CLEANING SOLVENT HAZARD Many cleaning solvents can degrade plastic parts and cause them to fail, which could cause serious injury or property damage. • Use only compatible solvents to clean plastic structural or pressure-containing parts. • See Technical Specifications in all equipment manuals for materials of construction.

  • Page 5: Before You Start

    Before You Start Before You Start Pressure Relief Procedure Follow the Pressure Relief Procedure whenever you see this symbol. Grease Fittings a. Lubricate all grease fittings using a grease gun and verify that every grease point is accepting grease. b. Use a clean cloth or rag to remove any This equipment stays pressurized until pressure is remaining grease, contaminants or dirt from the manually relieved.

  • Page 6: Typical System Installation

    Typical System Installation Typical System Installation Key: Banjo Bolt / Pump Outlet Feed Line Tubes Power Connector Manual Run Button (located in truck cab) Power Cable/Remote Run Button Cable Instruction Label (located in truck cab) ™ USB Port (DMS Models only) Pump T-Fitting - Pump to Main Feed Hose (M) 31 Reservoir...
  • Page 7 Typical System Installation 3A5082G...

  • Page 8: Pump

    Pump Pump Part No: 24Z764 - 12 Volt Standard 24Z959 - 24 Volt Standard 26C494 - 12 Volt, DMS with follower 26C495 - 12 Volt Standard 1000psi 24Z660 - 12 Volt, DMS and Illuminated Remote Run Button 24Z958 - 24 Volt, DMS and Illuminated Remote Run Button...

  • Page 9: Parts: 24Z660, 24Z958, 24Z764, 24Z959, 26C494, 26C495, 26A848

    Pump Parts: 24Z660, 24Z958, 24Z764, 24Z959, 26C494, 26C495, 26A848 Part No. Description Part No. Description PADDLE, low level BASE, with control PADDLE, stirring 278142 COVER, bottom, w/seal WIPER, stirring 115477 SCREW, mach, orx pan hd SCREW, M6 13 124396 O-RING, 258, BUNA-N,...

  • Page 10: Parts: 24Z660, 24Z958, 24Z764, 24Z959, 26C494, 26C495, 26A848

    Pump Parts: 24Z660, 24Z958, 24Z764, 24Z959, 26C494, 26C495, 26A848 25/26 3A5082G...

  • Page 11: Pump Dimensions

    Pump Pump Dimensions 3A5082G...

  • Page 12: Choosing An Installation Location

    . 8. NOTE: Mounting bracket, Part No. 17S107, suitable for mounting on most truck frames, is available from Graco. Contact your local Graco distributor for assistance with ordering this part. See F . 9, page 13 for bracket with pump dimensions.
  • Page 13 Pump Mounting Bracket and Pump Dimensions 3A5082G...
  • Page 14 Pump Pump Wiring Diagram (Standard Models: 24Z764, 24Z959, 26C494, and 26C495) The pump requires a 2-wire, CPC Connector Cable (Part No. 129644) to power the pump. See the Wiring Schematic provided in F . 10. . 10 Pump Wiring Diagram (Models with DMS and Illuminated Remote Run Button: 24Z660, 24Z958, 26C494 and 26A848) The pump requires a 5-wire, CPC Connector Cable (Part No.

  • Page 15: Low Level Fault/Warning

    To avoid equipment damage: • Never operate pump without a fuse installed. • A fuse of the correct voltage must be installed in line with the power entry to the system. Graco Fuses Part No. Description Amps 25C985 12 VDC...
  • Page 16 Pump Illuminated Remote Run Button Available on DMS enabled models only. 3. Insert the push button (51) through the hole drilled through the panel in Step 1. Hand tighten the lock nut (1a) to secure the push button in place (F .

  • Page 17: Tri-Color Remote Illumination

    Direct Mount Vent Valve The Direct Mount Vent Valve is installed on the pump when it is shipped to the customer from Graco. Vent Valve Replacement Kits 25C965 (2000 psi) and 26C493 (1000 psi) for 12 Volt pumps and 25C966 (2000 psi) and 26A856 (1000 psi) for 24 Volt pumps are available from Graco.

  • Page 18: Pump Setup

    Pump Pressure Relief Valve (F . 18, R) 1. Remove dust cap (26) and connect fill hose to inlet fitting (25) (F . 20). The pressure relief valve is preset to 1000 psi 6.895 MPa, 68.95 bar) or 2000 psi (13.79 MPa, 137.9 bar). DO NOT ADJUST THIS SETTING.

  • Page 19: Priming

    Pump NOTE: The reservoir air vent (P), located in rear of Priming reservoir, should not be used as an overfill port/indicator. NOTE: It is not necessary to prime the pump every time the pump is filled with lubricant. The pump only requires priming the first time it is used or if it is allowed to run dry.

  • Page 20: Programming The Pump

    Pump Programming the Pump Control Panel Overview (F . 26) NOTE: Programming instructions begin on page 21. OFF TIME • LED lights when OFF Time is DISPLAY used to control Pump OFF • A blinking LED under HH, MM, SS function.

  • Page 21: Quick Setup Guide - Dms And Illuminated Remote Run Models

    . 27 The controller does not require a user to provide a PIN code to access the programming features of the unit. However, Graco understands that some users may want Pump Software to protect the programming settings and therefore, an option for adding PIN Code authorization is available.
  • Page 22 Pump Enter the Month: If the PIN Code you entered is correct, the first editable character on the display will flash. NOTE: A blinking field on the display indicates the pump is in SETUP MODE. In RUN MODE numbers on the display will not blink.
  • Page 23 Pump Enter the Time: 5. The next number field to the right blinks and the LED under the MM lights indicating the is ready to • The time displays in 24-Hour format. i.e., 2:45 PM program the minutes fields. displays as 14:45. 6.

  • Page 24: Pump Off / Rest Setup

    6. After pressing the ENTER button to set If this time does not meet the application needs, the last SS field, all the programmed ON contact Graco Customer Support. Time information is saved. Programming OFF Time The automatically switches to the OFF Time SETUP MODE.

  • Page 25: Dms ™ Models

    The pump program settings file is named: the desired number appears in the second HH number GRACO/Config/config.bin. This file cannot be modified. field. Modification of the file or file name may cause it to be 4. Press the ENTER button to lock in the unusable.
  • Page 26 Log Name • DMS ID Number 8. When upload is finished, “done” is displayed. • Current Software Graco Part No. • Current Software Version 9. The pump resumes. • Date and Time of Upload 10. Remove the USB flash drive.
  • Page 27 Pump Sample System Event Log Example Event Log: The pump cycle of a typical lubrication system is shown below. System Event Log DMS ID Number: 00613 Software Part No.: 17J936 Software Version: 0703 09/29/2016 14:1400 Date Time Description 9/29/2016 14:13:02 Pump Run Off 9/29/2016 14:13:02...

  • Page 28: Error Log

    Operating outside of The log file is stored as: the specified temperature range may cause reduced GRACO/{DMS_id}/{download date - performance and possible unit YYYYmmDD}/ERRORLOG.CSV failure. Motor Overcurrent The unit is out of expected Example: GRACO/00613/20160911/ERRORLOG.CSV.
  • Page 29 Pump USB File Not Found The pump program setting file was not found or created correctly. Restore the setting file to the flash drive. USB Folder Navigation The pump program setting file was not found or created correctly. Restore the setting file to the flash drive.

  • Page 30: Functional Summary

    This is very similar to an odometer in your car. Technical User Summary, page 33). The log file is stored as: This is very similar to the resettable trip odometer in your car. GRACO/pump_{DMS_id}/{download date - YYYYmmDD}/FUNCSUM.CSV Example: GRACO/pump_00025/20100911/FUNCSUM.CSV Sample Functional Summary...

  • Page 31: Technical Summary

    The average percentage of time The log file is stored as: the unit has been pumping while it has been powered on. GRACO/{DMS_id}/{download date - Max Duty Cycle The highest percentage of time YYYYmmDD}/TECHSUM.CSV for one lubrication cycle that the unit has been pumping while it Example: GRACO/00025/20100911/TECHSUM.CSV...

  • Page 32: Advanced Programming

    Pump Sample Technical Summary Functional Summary DMS ID Number:00613 (Hold Down Arrow On Pump to View) Software Part No.: 17J936 Software Version:0703 9/13/2016 11:15:35 Latest Values Temp Voltage 11.846 Type Start Date Average Peak Average Peak Average Peak Board Board Motor Motor Internal...
  • Page 33 Pump 4. The cursor automatically is Selecting Advanced Setup Options positioned to entered the first 1. Press the UP or DOWN character of the PIN Code. ARROW button to move up or Use the UP and DOWN down between Advanced ARROW buttons to move up Options.

  • Page 34: Time Control

    Pump A10 - Low Level Reset Upon Power On. 3. Press the ENTER button. (Models with Firmware 5.04 and later. DMS Models with Firmware 7.07 and later.) Time Control This function changes the behavior of the low level upon After setup is complete, the pump automatically begins pump power on.
  • Page 35 Pump Cold Delay In DMS models, when the pump powers on when the temperature is below 14°F (-10°C), there is a 15 minute cold delay before the pump resumes running the program. When power to the unit cycles OFF then ON. Temperature is below14°F (-10°C).

  • Page 36: Alarms

    Pump Alarms Any time a Fault / Warning occurs, a combination of LED’s will illuminate to notify you there is a problem and help identify the kind of Fault / Warning has occurred. • Faults and Warnings will not automatically clear. •...
  • Page 37 Unit stops pumping and and hold the displays amount of RESET button to clear accumulated time since the fault. alarm was triggered. System An internal fault has Contact Graco Customer Fault occurred. Service. 3A5082G...
  • Page 38 Examine pump to ensure damage. that it is rotating properly. Pump tries running cycle If necessary, contact 90 times before shutting Graco Customer Service. down. See Pump Over-current Protection, page 15. Motor The measured motor Examine system to make...
  • Page 39 F to 158° F (-25° C to Use of the unit outside of 70°C). the recommended temperature range could If necessary contact cause degraded system Graco Customer Service. performance and possible damage. USB Error An error occurred during a Read the Troubleshooting DMS operation.

  • Page 40: Fault/Warning Scenarios For Firmware Versions 5.06 And Later For Non-Dms Models And 7.09 And Later For Dms Models

    Pump Fault/Warning Scenarios for Firmware Versions 5.06 and Later for Non-DMS Models and 7.09 and later for DMS Models Alarm Type What it Looks Like What it Indicates Solution Low Power If there is a voltage drop at Check voltage and Warning the power source during available current output at...

  • Page 41: Testing Installation

    Pump Testing Installation NOTE: Complete instructions for programming the Electric Grease Jockey pump begin on page 59. 1. Power up pump and enter Setup Mode by pressing both the UP and DOWN ARROW buttons together for 3 seconds. 2. Button will flash green. 3.

  • Page 42: Manifold

    Manifold Manifold There are two manifold sizes. • 6 port manifold - used in lubrication systems with 6 or less lubrication points (F . 32 and F . 34). • 12 port manifold - used in lubrication systems with 7 to 12 lubrication points (F .

  • Page 43: Manifold Dimensions

    Manifold Manifold Dimensions 6 Point Manifold Dimensions 12 Point Manifold Dimensions . 34 . 35 Injector Manifold Assembly Injector outputs can be combined for a common bearing NOTE: The inlet port on the 12 point manifold (120) point with a large grease requirement but the output for can be installed in the side or top inlet port.

  • Page 44: Injectors

    Injectors Injectors Parts Part No Description SEAL, gasket BODY, injector CUP, retaining 556586 O-RING, 5-058 556660 NUT, sleeve assembly, 3/16 tube SPACER, output, model 24Z682; injector size #0 SPACER, output, model 24Z683; injector size #1 SPACER, output, model 24Z684; injector size #2 557898 SPACER, output, model 24Z685;...

  • Page 45: Adjusting Grease Output Volume

    Injectors Adjusting Grease Output Volume Grease injectors are used to provide precise lubrication to each grease point in the system. If an injector is not producing the correct amount of lubricant for a specific location on the vehicle or if a replacement injector of correct size is not available, output spacer washers (110) can be installed to adjust the injector’s output volume (F .

  • Page 46: Manifold Installation

    Injectors 4. Add or remove output spacers (110) (F . 39, page • The unused ports in the manifolds should have 45) from the injector valve assembly. plugs in them. If additional lube points are needed these plugs can be removed and replaced with NOTE: appropriate sized injectors and lines.

  • Page 47: Modules

    Modules Modules NOTE: All installations may not include all points listed. The illustrations and instructions shown in the Modules section of this manual are provided for reference only. They may not be an exact representation of your truck or equipment. Lubrication points and locations are unique to each vehicle and installation will vary from vehicle to vehicle.
  • Page 48 Modules Installation Instructions depending on the routing of the main line. Alternate ports are on each end of the module. 1. Tie wrap the 3-tube bundle, 2-tube bundle and (2-tube #2, if present) marked bundle together as a 10. Optional: Ports 7 & 8 on the modules are used for group.
  • Page 49 Modules Front Right Module (F . 43) Recommended Lube Point Point No. Description Injector Size Tube Color Bundle Fitting P/N SPRING SHACKLE Orange 556638 Elbow 2-Tube #1 SPRING SHACKLE Black 556638 Elbow PLUG PLUG 15K783 St Elbow and 556644 CLUTCH C/SHAFT LH Black 2-Tube Connector...
  • Page 50 Modules Installation Instructions 9. The lube line for the spring pin is black and single. Route the line so it will be supported every 12-15 1. Tie wrap the 3-tube bundle and 2-tube #2 marked inches of travel. bundle together as a group. These will follow the air brake line over the wheel area.
  • Page 51 Modules Tandem Axle Module (F . 45) Recommended Lube Point Point No. Description Injector Size Tube Color Bundle Fitting P/N PLUG PLUG “S” CAM Black 556638 Elbow 2-Tube Unmarked SLACK ADJUSTER Orange “S” CAM Black 2-Tube Unmarked SLACK ADJUSTER Orange SLACK ADJUSTER Orange 2-Tube...
  • Page 52 Modules Installation Instructions 1. Run each twin line to the brake slack adjuster and “S” cam following the air hoses from the control valve to the brake cams. This will allow for enough slack in the lines for axle movement. 2.
  • Page 53 Modules 5th Wheel Module (F . 47) Point No. Description Injector Size Tube Color Bundle Recommended Fitting P/N FIFTH WHEEL PLATE Orange FIFTH WHEEL PIVOT Black 3-Tube FIFTH WHEEL PLATE Blue 556644 Connector or 556638 Elbow FIFTH WHEEL PLATE Blue 3-Tube FIFTH WHEEL PIVOT Black...

  • Page 54: Feed Line Tubes And Fittings

    Feed line tubes (H) come pre-filled with grease. The following tube bundles may be included with the system. General Installation Instructions Other tube lengths are available from Graco. Contact NOTE: For specific installation instructions for each your local Graco distributor or Graco Customer Support Module, see Left Front, Right Front, Rear and 5th Wheel for assistance.

  • Page 55: Feed Line Fittings

    Feed Line Tubes and Fittings 5. Make sure the tube is well seated into each fitting. Feed Line Fittings Hand tighten the tube nut onto the injector and Straight Connector - Part No. 556644 tighten 1 full turn beyond hand tight. DO NOT OVERTIGHTEN.

  • Page 56: Main Line Hose

    Main Line Hose Main Line Hose Determining Main Line Hose Lengths Temperature Electric Grease Jockey hoses are available in three lengths. One end is crimped in the factory the other end Do not exceed the fluid and / or ambient temperature comes with a reusable fitting.

  • Page 57: Main Line Hose Assembly

    Main Line Hose Main Line Hose Assembly SKIN INJECTION HAZARD A hose that has been crushed or damaged in the vise may leak. High pressure fluid leaks will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation.

  • Page 58: Main Line Fittings

    Main Line Hose 6. Secure socket (a) in vise. Lubricate nipple (c) and 8. Leave 1/32 to 1/16 inch (0.79 to 15.87 mm) threads liberally with grease. clearance between socket (a) and hex (d) (F . 62). 1/32 in. to 1/16 in. (0.79 to 15.87 mm) .

  • Page 59: System Starting And Operation

    System Starting and Operation System Starting and Operation AUTOMATIC SYSTEM ACTIVATION HAZARD The system is equipped with an automatic timer that activates the pump lubrication system when power is connected or when exiting the programming function. grease Unexpected activation of the system could result in serious injury, including skin injection and amputation.
  • Page 60 System Starting and Operation NOTE: This the factory set OFF time. 7. The cycle then repeats. NOTE: See Programming the Pump, page 21 for instructions to increase or decrease cycle time. . 67 Typical Cycle The illustration shown in F .

  • Page 61: Troubleshooting

    Troubleshooting Troubleshooting Problem Cause Solution Too much grease at all lube points Lube cycle too frequent Increase pump OFF/rest time. Too much grease at one lube point Injector is leaking Remove and replace injector Not enough grease at all lube points Lube cycle is too infrequent Decrease pump OFF /rest time.
  • Page 62 Retry using a different flash USB Error 07 drive. If any of the above do not rectify the error, contact Graco Customer Service. Pump program setting file not found Verify that the pump program setting folder structure and file are stored correctly on the flash drive.
  • Page 63 Unplug the flash drive and reinstall. • Cycle power and re-install the All other USB errors flash drive. • Retry using a different flash drive. If any of the above do not rectify the error, contact Graco Customer Service. 3A5082G...

  • Page 64: Maintenance

    Maintenance Maintenance Frequency Component Required Maintenance Keep refill fitting clean by covering it Daily and at refill Refill Fitting with dust cap (26) when not in use. Clean refill fitting using a clean dry cloth. Dirt and/or debris can damage pump and/or lubrication system.

  • Page 65: Technical Specifications

    Technical Specifications Technical Specifications Grease Jockey Automatic Lubrication System Metric 2000 psi 13.79 MPa, 137.9 bar Maximum fluid working pressure 1000 psi 6.89 MPa, 68.9 bar Fluid Grease NLGI 000 - #2 Grease Jockey Pump Pump Output Pressure 2000 psi 13.79 MPa, 137.9 bar Power 12 VDC...
  • Page 66 Technical Specifications Grease Jockey Automatic Lubrication System Metric Injectors Maximum Operating Pressure 2000 psi 13.79 MPa, 137.9bar Minimum Operating Pressure 450 psi 3.2 MPa, 31.5 bar Reset Pressure 250 psi 1.72 MPa, 17.24 bar Output Volume per Cycle Size 0 injector 0.002 cu.

  • Page 67: Notes

    Notes Notes 3A5082G...

  • Page 68: Graco Ile On-Road Electric Grease Jockey (Egj) Warranty

    With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of sixty (60) months from the date of sale, repair or replace pump, pump element, injector meters and modules ("EGJ Parts") that are part of an ILE On-Road Electric Grease Jockey system, and only such EGJ Parts that are determined by Graco to...

This manual is also suitable for:

24z66024z95824z95926c49426c49526a848

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