OM4203 Automatic Lubrication System - Section 42 42-13 PREVENTATIVE MAINTENANCE PROCEDURES The following maintenance procedures should be used to insure proper system operation. 4. Inspect all bearing points for a bead of lubricant around the bearing seal. It is good practice to manually lube each bearing point at the grease fitting provided on each Injec- tor. This will indicate if there are any frozen or plugged bearings, and will help flush the bearings of contaminants. Daily Lubrication System Inspection 1. Check grease reservoir level. Inspect grease level height after each shift of operation. Grease usage should be consistent from day-to-day operations.
Lack of lubricant usage would indicate an inop- erative system. Excessive usage would indicate a broken supply line. 5. System Checkout a. Remove all SL-1 injector cover caps to allow visual inspection of the injector cycle indicator pins during system operation. 2. Check filter bypass indicator when filling reser- voir. Replace element if bypassing. b. Start truck engine. 3. Check all grease feed line hoses from the SL-1 Injectors to the lubrication points. c. Actuate the lube system manual test switch (17, Figure 42-2). The hydraulic motor and grease pump should operate. a. Repair or replace all damaged feed line hoses. d. With the grease under pressure, check each SL-1 injector assembly.
The cycle indicator pin should be retracted inside the injector body. b. Make sure that all air is purged and all new feed line hoses are filled with grease before sending the truck back into service. 4. Inspect key lubrication points for a bead of lubri- cant around seal. If a lubrication point appears dry, troubleshoot and repair problem. e. When the system attains 2500 psi (17 237 kPa), the pump should shut off and the pres- sure in the system should drop to zero, venting back to the grease reservoir. 250 Hour Inspection f. With the system vented, check all of the SL-1 injector indicator pins; all of the pins should be visible. Replace or repair injectors, if defective. 1.
Check all grease feed line hoses from the SL-1 Injectors to the lubrication points (see, Figure 42- 2). g. Reinstall all injector cover caps. a. Repair or replace all worn / broken feed line hoses. h. Check timer operation. b. Make sure that all air is purged and all new feed line hoses are filled with grease before sending the truck back into service. Note: With engine running, lube system should activate within 5 minutes. The system should build 2000 to 2500 psi within 25-40 seconds. 2. Check all grease supply line hoses from the pump to the SL-1 injectors. i. If the system is working properly, the machine is ready for operation. a. Repair or replace all worn / broken supply lines. j.
If the system is malfunctioning, refer to the troubleshooting chart. b. Make sure that all air is purged and all new supply line hoses are filled with grease before sending the truck back into service. 1000 Hour Inspection 3. Check grease reservoir level. 1. Check pump housing oil level. Refill to bottom of level plug with SAE 10W-30 motor oil if necessary a. Fill reservoir if low. Check filter bypass indica- tor when filling reservoir. Replace element if bypassing. b. Check reservoir for contaminants. Clean, if required. c. Check that all filler plugs, covers and breather vents on the reservoir are intact and free of contaminants.