HIGH CHIEF HYDRAULIC OPERATED

GREASE PUMP
High Chief Models 03-000920, 03-000921, 03-000950-AUS, 03-000950-USA,
03-000951-AUS, 03-000951-USA, 03-000954, 03-000955, 03-000964
Revision 4.0, Jan 2017
PART NUMBER: 03-000920, 03-000921 for 20kg pail
03-000950-USA, 03-000951-USA for 60kg drum
03-000950-AUS, 03-000951-AUS for 60kg drum
03-000954, 03-000955 for 180kg drum
03-000964 for mini drums
SPECIFICATION: Supply Inlet Pressure: 20-200bar
Hydraulic Inlet Flow: 0.25-3.0L/m
Output Pressure: 300 bar
Operating Temp: -100C to +600C
Operating Voltage: 24VDC
Hydraulic Inlet Port: 7/16” JIC
Tank Return Port: 9/16” JIC
Pump Outlets: ¼” NPT
Max. Hyd. Fluid Temp: 980C
Output per cycle: 8.8cm3/cycle

FACTORY SETTINGS: Output: 132cm3/minute

DESCRIPTION It is the owner / operator

Models 03-000920, 03-000950-
AUS, 03-000950-USA, 03-000954,
03-000964 are hydraulically
operated grease pumps using a
reciprocation timer (03-000014-2).
Models 03-000921, 03-000951-
AUS, 03-000951-USA, 03-000955
are hydraulically operated grease
pumps with no timer but designed to
be used in conjunction with the JSG
“G2” dual controller (13-002500)
which has two control outputs, one
output controlling the pump speed
the second output controlling the
pump on time and the lubrication
cycle. All models are designed for
centralised lubrication systems for
any equipment which utilises 24VDC
power source. (With “G2” Timer can
use 12VDC)
OWNER/OPERATOR
RESPONSIBILITY
It is the owner/operator
responsibility to properly use and
maintain this equipment.
The instructions and warnings
contained in this manual shall be
read and understood by the
owner/operator prior to operating
equipment.
If an owner/operator does not
understand English, a request must
be made to have the contents of this
manual explained in the
owner/operator native language to
assure the owner/operator
comprehends.
responsibility to maintain the
legibility of all warning and
instruction labels.
The owner/operator shall retain this
manual for future reference to
important warnings, operating and
maintenance instructions.
WARNING
FAILURE TO HEED THE FOLLOWING
WARNINGS INCLUDING MISUSE,
OVER PRESSURISING, MODIFYING
PARTS, USING INCOMPATIBLE
CHEMICALS AND FLUIDS, OR USING
WORN OR DAMAGED PARTS, MAY
RESULT IN EQUIPMENT DAMAGE
AND/OR SERIOUS PERSONAL
INJURY.
 Do not exceed the stated maximum
working pressure of the pump or of
the lowest rated component in your
system.
 Do not alter or modify any part of this
equipment.
 Do not attempt to repair or
disassemble the equipment while the
system is pressurised.
 Make sure all fluid connections are
securely tightened before using this
equipment.
 Always read and follow the Fluid
manufacturer’s recommendations
regarding fluid compatibility, and the
use of protective clothing and
equipment.
 Check all equipment regularly and
repair or replace worn or damaged
parts immediately.

JSG INDUSTRIAL SYSTEMS PTY LTD Page 1

 HIGH CHIEF MANUAL
Revision 4.0, Jan 2017

BASIC PUMP DRUM SIZE DIMENSION A

03-000920, 03-000921 20kg 479 mm
03-000950-USA, 03-000951-USA 60kg 695 mm
03-000950-AUS, 03-000951-AUS 60kg 556 mm
03-000954, 03-000955 180kg 862mm
03-000964 Mini Pump 350mm
Figure 1. General information

SAFETY INSTRUCTIONS Specialised equipment and

This equipment generates very high
grease pressure. Extreme caution
should be used when operating this
equipment as material leaks from
loose or ruptured components can
inject fluid through the skin and into
the body causing serious bodily
injury including possible need for
amputation. Adequate protection is
recommended to prevent splashing
of material onto the skin or into the
eyes.
IMPORTANT
If any fluid appears to penetrate
the skin, get emergency medical
care immediately. Do not treat
as a simple cut. Tell attending
physician exactly what fluid was
injected.
WARNING knowledge is required for repair of
this pump.
DO NOT alter or
Contact JSG Industrial Systems or
modify any part of your nearest authorised JSG service
the equipment as centre for repairs or adjustments
other than maintenance specified in
this may cause a this manual.
malfunction and
result in serious Annual inspection by JSG Industrial
bodily injury. Systems is recommended.
DAMAGED PUMPS
INSPECTION Any pump that appears to be
damaged in any way, is badly worn
If over pressurising of the equipment
or operates abnormally shall be
is believed to have occurred, contact
JSG Industrial Systems or your removed from use until repairs are
nearest service centre. made. Contact JSG Industrial
Systems for repairs.

JSG INDUSTRIAL SYSTEMS PTY LTD Page 2


NOTE:
THE THEORETICAL RATIO OF THIS PUMP IS 15:1
DEPENDANT ON THE APPLICATION AND
VARIABLE INTERNAL FRICTION; THE ACTUAL
RATIO MAY BE LESS.
HYDRAULIC MOTOR
OPERATION
This section describes the operation
of the hydraulic Motor Assembly.
(See Figure 2)
WARNING
Maximum allowable output
pressure of this pump is 360
bar. Be sure that all system
equipment and accessories are
rated to withstand the
maximum working pressure of
this pump. DO NOT exceed the
maximum working pressure of
the lowest rated component in
the system.
The “P” port should be connected to
a suitable hydraulic supply,
preferably to a pilot system.
The “T“ port is the return to tank line.
The “P1” port is an auxiliary port,
which is normally left plugged. It is
suitable for use as a gauge port or if
necessary to operate a hydraulic
vent valve. If a gauge is connected
to the “P1” port it will show the 20
bar setting of the integral pressure
Reciprocation solenoid valve
reducing valve. During operation the
pressure gauge reading will fluctuate
in time with the reciprocating rate of
the pump.
NOTE:
If operating vent valve (01-084980)
from auxiliary port “P1”, an orifice
(03-247384) must be fitted. When
ordering the orifice please state
version of reciprocating assembly
you have. With this setup an
additional hydraulic 2/3 way shut off
valve must be fitted in the hydraulic
supply line. See Fig. 14 for wiring
diagram.
The pump operates as follows:
The reciprocation timer used in
models 03-000920, 03-000950-AUS,
03-000950-USA, 03-000954, (03-
000014-2) determines the number of
cycles per minute. (The factory
setting is 2 seconds on & 2 seconds
off, which results in 15 cycles /
minute.)
By utilising the JSG “G2” timer with
the High Chief Hydraulic Pump
models 03-000921, 03-000951-AUS,
03-000951-USA & 03-000955 this
cycle can be adjusted to whatever
required reciprocation rate however
JSG INDUSTRIAL SYSTEMS PTY LTD
HIGH CHIEF MANUAL
Revision 4.0, Jan 2017
Figure 2 – Pump
motor circuit
2 seconds on and 2 seconds off is
the factory recommendations.
In the Rest State hydraulic pressure
is normally applied to the top of the
Motor, holding the piston at the end
of its down stroke.
Applying 24 volt DC Power to the
reciprocation timer (03-000014-2)
will start the reciprocating action by
operating the solenoid valve, thus
sending the piston to the top of its
stroke and then back again, at the
rate set by the timer. Turning the 24-
volt supply off will stop the
reciprocation timer thus interrupting
the power to the solenoid and return
the piston to its rest position at the
bottom of its stroke.
WARNING
A pressure switch and safety
valve must be used in the
lube system. The cylinder
pressure must not exceed 20
bar. Failure to use these
monitoring and safety
devices may result in damage
to system components and
personal injury!
Page 3

Figure. 3 – Pump motor with reciprocating timer
There are two LED lights under the
opaque cover of the reciprocation
timer. (See figure 3) One indicates
that power is applied the other blinks
on and off as it operates the
reciprocation solenoid valve.
TROUBLE SHOOTING
If the following procedures do not
correct the problem, contact JSG
Industrial Systems Pty Ltd or a JSG
authorised service centre. When
submitting equipment to be repaired,
be sure to state the nature of the
problem and indicate if a repair cost
estimate is required.
PROBLEMS
No or low hydraulic pressure at
the Auxiliary port.
A. No system pressure to the
pump.
B. Pressure reducing valve set to
low. Increase setting by ½ turn
to check operation.
HIGH CHIEF MANUAL
Revision 4.0, Jan 2017
Pump pressure builds very G. Replace shovel rod if rough or
slowly or not at all pitted. Replace shovel rod
packing.
A. No pulsing signal from H. Inspect lubricant supply line for
reciprocation timer. leaks or breaks.
B. Pressure reducing valve may be I. If hydraulic vent valve is used
set to low. then an orifice (03-247384)
must be fitted in “P1” auxiliary
C. Grease viscosity may be too port. Problem can be caused
high for temperature at which either by missing orifice or clog-
pump is operating. ged orifice (see note page 3.)
D. If pressure is not building at all,
the reciprocation solenoid may
be inoperative.
E. Pump piston ball checks and
inlet checks may have foreign
matter trapped causing leakage.
Remove, inspect and clean if
necessary.
F. Inspect sealing surfaces
between upper and lower inlet
checks. Replace if rough or
pitted.
JSG INDUSTRIAL SYSTEMS PTY LTD Page 4

DISASSEMBLY
Refer to SERVICE PARTS for part
numbers and location. Bleed all
pressure from hydraulic and grease
lines before disassembling pumps.
A. Remove nut securing solenoid
coil. Remove the coil together
with the reciprocation timer.
B. Remove socket head cap
screws securing reciprocation
valve assembly and remove
assembly.
C. Remove socket head screws
securing hydraulic cylinder top
(03-000013-1) and remove top.
D. Remove hydraulic cylinder.
E. Remove cylinder tie rods by
unscrewing them from outlet
body.
F. The cylinder bottom will now be
partially free of the outlet body
(03-001311)
G. Unscrew pump tube from outlet
body (03-001311).
H. Extend pump piston rod (01-
011340) out of the bottom of
outlet body (03-0001311). Place
wrenches on piston rod end and
flats of piston boss (03-000013-
6) and flats of piston rod (01-
011340) and unscrew piston
rod. Thread the piston rod
through the gland packing to
allow removal of the pump tube.
I. Unscrew gland packing nut (01-
012333) from outlet body and
remove all gland parts.
J. Remove the priming tube (01-
239719) from the bushing
extension (01-061273).
K. Extend plunger rod (01-011723)
out of bushing extension and
unscrew priming extension (01-
011724) to allow removal of
priming check parts and plunger
rod (01-011723).
L. Remove bushing extension (01-
061273) and unscrew plunger
bushing assembly (01-090554)
from pump tube. Unscrew
coupling nut (01-011344) to
allow removal of plunger and
bushing assembly intact,
reducing the chance of losing
ball stop (01-057027) and check
ball (01-066010).
ASSEMBLY
To reassemble, perform
DISASSEMBLY procedure in
reverse.
IMPORTANT
To prevent damage to pump gland
packing and to help increase
packing life, lube pump piston rod
before assembly. Thread piston
rod through gland packing when
assembling pump.
REPAIR
Repair is limited to replacement of
listed service parts. Special
procedures and tools are required.
Contact JSG Technical service for
details and your nearest authorised
service centre.
When ordering replacement parts,
list the part number, description,
model number and series letter of
the product to be repaired.
ACCESSORIES
01-245530 Viton / Teflon kit
(For Pumping
Synthetic
Lubricants)
01-083001 Lower Pump
Tube repair Kit
03-000920-9V Hydraulic
cylinder seal kit.
JSG INDUSTRIAL SYSTEMS PTY LTD
HIGH CHIEF MANUAL
Revision 4.0, Jan 2017
JSG OFFICE LOCATIONS
Head Office
Phone: (02) 9914 8720
Fax: (02) 9774 2321
Email: jsgindustrial@jsg.com.au
Web: www.jsgindustrial.com
Newcastle Office
Phone: 0447 277 755
Email: jsghv@jsg.com.au
Brisbane Office
Phone: (07) 3273 3433
Fax: (07) 3273 3369
Email: jsgqld@jsg.com.au
Townsville Office
Phone: (07) 4772 5454
Fax: (07) 4724 5951
Email: jsgfnq@jsg.com.au
North Mackay Office
Mobile: 0448 022 886
Fax: (07) 4946 5466
Email: jsgcq@jsg.com.au
Melbourne Office
Phone: (03) 9762 4744
Fax: (03) 9762 4772
Email: jsgvic@jsg.com.au
Perth Office
Phone: (08) 9248 7311
Fax: (08) 9248 9817
Email: jsgwa@jsg.com.au
Adelaide Office
Phone: 0448 730 886
Fax: (08) 8240 3966
Email: jsgsa@jsg.com.au
AUTHORISED SERVICE
CENTRES THROUGHOUT:
New South Wales, Queensland,
Victoria, South Australia, Western
Australia, Tasmania, Northern
Territory, Indonesia, Papua New
Guinea, New Caledonia, Fiji, New
Zealand
Page 5

Service Replacement
pump. Figure 4 & 5
Model 03-000921
Used only in conjunction with the
G2 controller
Service Replacement pump for:
Pump station Model 03-000555BF
Ref: Fig 4 shows pump with cover.
Fitted & Fig 5 shows pump with
cover removed.
Service Replacement pump for:
Pump station Model 03-000555BF
Ref: Fig 4 shows pump with cover
fitted. & Fig 7 shows pump with
cover removed.
Early Model Service Replacement
pump for: Pump Station Model 03-
000555
Ref Fig 4 shows pump with cover
fitted & Fig 8 shows pump with
cover removed.
HIGH CHIEF MANUAL
Revision 4.0, Jan 2017
Figure 5: Close view of the head of the pump model 03-000921
In this we can see the plug is connected directly to the solenoid coil.
This model pump is without reciprocation cycler. & therefore this
Figure 4
pump must be controlled with G2 controller. The two outputs from a
Replacement
G2 controller can pulse the solenoid directly & control the vent
pump
valve at the same time. See Fig. 13 for wiring diagram.
P/No. 03-000921
- +
Figure 7
P/No 03-000014-2
(includes plug
Figure 6
connector)
P/No. 03-000920 shown with cover removed.
This model includes a reciprocation cycler.(Ref : Fig 7). Pumps Shown above with-out
with reciprocation cycler can be controlled with a Lube plug connector.
Management controller. See Fig. 12 for wiring diagram.
Figure 9
P/No. 03-00014 now
replaced by 03-
Figure 8 000014-2 Ref: Fig 7
P/No.03-000920 shown with cover removed. It is shown above
with the early Model reciprocation cycler. Ref: Fig 9
JSG INDUSTRIAL SYSTEMS PTY LTD Page 6
 HIGH CHIEF MANUAL
Revision 4.0, Jan 2017

Gland Assembly Note: 2 x thin washers P/No

01-048213 and 1 x copper gasket P/No 01-031050 must be
assembled as shown in the diagram. After the nut P/No 01-
012333 has been tightened check for proper compression of
01-012333
the copper gasket by trying to move the top thin washer
P/No 01-048213 with a screw driver. It should be possible to
just move the washer. If the thin washer cannot be moved
check to see if the copper gasket P/No 01-031050 is in 01-048213
03-38165V
place or the correct thin washer P/No 01-048213 has been
01-031050
used. 01-034572

03-016576
01-034572

03-38165V

01-048213

01-011349
USE LOCKTITE 510
GASKET ELIMINATOR
ON THREADS
01-031048
IMPORTANT
START FASTENERS BY HAND
TO AVOID STRIPPING
PUMP THREADS WHEN
TUBE REASSEMBLING.

01-057027
01-066010

PISTON
ROD

A
01-061407

01-011346
01-090554
01-011345
01-057027
01-066010
01-011344 01-31047

01-011726

01-011723

01-011722

01-035073

01-031049 01-011702

01-011721

01-011725

01-011724

01-061273

01-061275

Figure.10 – Exploded BOM for pump

BASIC PUMP PISTON ROD PUMP TUBE DRUM SIZE DIMENSION A
03-000920, 03-000921 01-011799 01-061293 20 kg 479 mm
03-000950-USA, 03-000951-USA 01-013020 03-000950-USATUBE 60 kg 695 mm
03-000950-AUS, 03-000951-AUS 01-011761 03-000950-AUSTUBE 60 kg 556 mm
03-000954, 03-000955 01-011761 01-246118 180kg 862 mm
03-000964 01-011064 01-061064 Mini Pump 350 mm
Note: 1. The Seal Kit Part No. 03-000920-9V is a combination of 7 seals for hydraulic cylinder.
2. Lower Pump Tube Kit Part No. 01-083001.
3. Gland Seals 1 x 01-031050, 2 x 03-038165V, 2 x 01-034572 not in kit. Order separately.

JSG INDUSTRIAL SYSTEMS PTY LTD Page 7

 HIGH CHIEF MANUAL
Revision 4.0, Jan 2017

TORQUE SPECIFICATIONS

1 14 Nm 4 108 Nm

2 41 Nm 5 122 Nm

3 61 Nm 6 136 Nm

Figure. 11 – Torque specification chart.

JSG INDUSTRIAL SYSTEMS PTY LTD Page 8

 HIGH CHIEF MANUAL
Revision 4.0, Jan 2017

PARTS LIST

PART NO. QTY DESCRIPTION PART NO. QTY DESCRIPTION

03-000013-1 1 Cylinder Top 01-011721 * 1 Priming check
03-000013-2 1 Cylinder 01-011722 1 Check stop
03-000013-3 1 Cylinder Base 01-011723 * 1 Plunger rod
03-000013-5 1 Valve Reciprocating Assy 01-011724 * 1 Priming plunger
03-000013-5-CS 1 Complete cartridge 2/4 way & 01-011725 * 1 Priming check seat
24VDC Solenoid
03-000013-5-PRC 1 Pressure Reducing Valve 01-011726 * 1 Check seat
03-000013-6 1 Piston (long boss) 01-031047 * 1 Check seat gasket
03-000013-7-2 4 Cylinder tie rods 01-031048 1 Connector gasket
03-000014-2 1 Reciprocation timer 01-031049 2 Bushing gasket
03-001311 1 Outlet steel body 01-031050 1 Gland gasket
03-016576 1 Gland packing spacer 01-031054 1 Pump tube gasket
03-0185-5704 6 + Set screws ¼” x 3/4” 01-034572 2 O-ring
03-0185-6606 2 Set screws ¼” x 2 3/4” 01-035073 * 1 Priming check pack’g
03-000920-9V 1 Seal kit (cylinder) 03-38165V 2 U-packing
01-011340 1 Piston rod 01-048213 2 Gland packing washer
01-011344 1 Plunger adaptor 01-057027 2 Ball stop
01-011345 1 Coupling nut 01-061273 1 Bushing extension
01-011346 1 Coupling nut 01-066010 * 4 Ball
01-011349 1 Piston rod connector 01-090554 1 Plunger & bushing assy
01-011702 * 1 Check washer 01-239719 1 Priming tube
 * Included in 01-083001 Lower Pump Tube Repair Kit.
 + 4 off required for Tie Rods, 2 off required for bottom section of valve

UPGRADE KIT 03-000940

from PILOT CHIEF to HIGH CHIEF
Hydraulic Motor End Only
PART NO. QTY DESCRIPTION
01-031050 1 Gland Gasket
01-031054 1 Copper Gasket
01-034572 2 O-Ring
01-048213 2 Packing Washer
01-083001 1 Repair Kit
03-001311 1 Outlet Steel Body
03-016576 1 Gland Spacer
03-038165V 2 U-Packing
03-000013-9V1 2 Viton O-Ring
03-000013-9V2 4 Viton O-Ring
03-000013-9V4 1 Viton O-Ring
03-000013-7-2 4 Tie Rods 3/8” UNC
NOTE: Kit does not include Cylinder or piston

JSG INDUSTRIAL SYSTEMS PTY LTD Page 9

 HIGH CHIEF MANUAL
Revision 4.0, Jan 2017

Figure. 12 - Detailed wiring

diagram for the connection
of the Lube Management
controller to the High Chief
Pump.

JSG INDUSTRIAL SYSTEMS PTY LTD Page 10

 HIGH CHIEF MANUAL
Revision 4.0, Jan 2017

Figure. 13 - Detailed
wiring diagram for the
connection of the JSG
“G2” Timer to the High
Chief Pump.

JSG INDUSTRIAL SYSTEMS PTY LTD Page 11

 HIGH CHIEF MANUAL
Revision 4.0, Jan 2017

Figure. 14 - Detailed
wiring diagram for the
connection with
hydraulic vent valve
using JSG “G2” Timer.

JSG INDUSTRIAL SYSTEMS PTY LTD Page 12

 HIGH CHIEF MANUAL
Revision 4.0, Jan 2017

PRODUCT DETAILS USING JSG “G2” TIMER

HIGH CHIEF PUMP HIGH CHIEF PUMP – COMPLETE TIMER “G2” TIMER 5 METRE
– NO TIMER WITH “G2” TIMER WITH 5M CABLE ONLY CABLE ONLY
03-000921 03-000921-T 13-002500 13-002500-1 13-002500-2
03-000951-### 03-000951-###-T 13-002500 13-002500-1 13-002500-2
03-000955 03-000955-T 13-002500 13-002500-1 13-002500-2
Note: Models 03-000920, 03-000950-AUS, 03-000950-USA & 03-000954 come fitted with a reciprocating timer 03-000014-2

For more technical detail on the JSG “G2” timer please refer to the “G2” manual.

Product Warranty

JSG Industrial Systems Pty Ltd (hereinafter called “JSG”) warrants that all products marketed by
JSG will be free from defects in material and workmanship during one (1) year period following
the date of purchase. If the equipment is deemed to be defective during this warranty
period, it will be repaired or replaced without charge, providing examination proved the
equipment to be defective. To obtain repair or replacement if must be shipped
”transportation charges prepaid”, with proof of date of purchase, to either JSG or one of its
authorised Service Centres within one (1) year following the date of purchase.

This warrant is extended to the original retail purchaser only. This warranty does not apply to
equipment damaged by accident, overload, abuse, misuse, negligence, faulty installation or
abrasive or corrosive materials, or to equipment repaired or altered by anyone not authorised
by JSG to repair to alter the equipment. This warranty applies only to equipment specified,
approved installed and operated according to the recommendations of JSG. No other
express warranty applies to lubrication equipment, material dispensing equipment, hose and
cable management equipment, or other related equipment supplied by JSG.

In no event shall JSG be liable for incidental or consequential damages. The liability of JSG on
any claim for loss or damage arising out of the sale, resale, or use of lubrication equipment,
material dispensing equipment, hose and cable management equipment, or other related
equipment shall in no event exceed the purchase price.

JSG INDUSTRIAL SYSTEMS PTY LTD Page 13