OM4202 Automatic Lubrication System - Section 42 Page 42-5 With the vent valve closed, the pump cycles until lubricant pressure reaches maximum pump output pressure* (pump stalls). As the grease supply line comes to maximum pressure, the injectors meter grease to the points of lubrication. This equipment generates very high grease pres- sure. 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 seri- ous bodily injury including possible need for amputation. Adequate protection is recom- mended to prevent splashing of material onto the skin or into the eyes. * WARNING:
Maximum pump pressure must not exceed 24.1 MPa (3500 psi). Exceeding this value will damage components and/or cause compo- nents to rupture, resulting in possible serious injury to any nearby personnel. If the pump stalls, SV2 will still be switching, and there will be no audible pause, as so with older style air pumps. 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. After approximately 75 seconds, the solid state sys- tem timer returns to the rest state, which de-ener- gizes the SV1 solenoid valve.
As SV1 is de-energized, the hydraulic supply to the pressure reducing valve and the vent valve is shut off, causing the vent valve to open. If over-pressurizing of the equipment is believed to have occurred, contact a factory authorized warranty and service center for inspection of the pump. Spe- cialized equipment and knowledge is required for repair of the pump or adjustments other than the maintenance specified in this chapter. When the vent valve opens, the pressure in the grease line is vented back to the grease reservoir and the line pressure drops to zero, so the injectors can recharge for their next output cycle.
Annual inspection by the factory authorized warranty and service center is recommended. The system is now at rest, ready for another lube cycle and the sequence to repeat itself. System Priming The system must be full of grease and free of air pockets to function properly. After maintenance, if the primary or secondary lubrication lines were replaced, it will be necessary to prime the system to eject all entrapped air. Over pressurizing of the system, 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 maximum pump pressure of 24.1 MPa (3500 psi).
• Do not alter or modify any part of this system unless approved by factory authorization. • Do not attempt to repair or disassemble the equipment while the system is pressurized. • Ensure all fluid connections are securely tight- ened before using this equipment. • Always read and follow the fluid manufacturer's recommendations regarding fluid compatibility, and the use of protective clothing and equip- ment. • Check all equipment regularly and repair, or replace, worn or damaged parts immediately. 1. Fill the reservoir with lubricant, if necessary. 2. Remove the plugs from all injector manifold dead ends and supply lines. NOTE:
To run the grease pump when priming the lube system, start the engine to energize the system. Connect a jumper wire between the LUBE SW and SOL terminals on the solid state timer. (Accumulators must be pressurized in order for the grease pump to operate. 3. Run the grease pump until grease flows from any one plug opening in the system. Replace the plug in this opening.