Automatic Lubrication System - Section 42 OM4202 Page 42-6 4. Repeat Step 3 until all lines are full and all plugs replaced. NOTE: Steering accumulator pressure is necessary to power the lube system for this procedure. Pressure Reducer Adjustment NOTE: Fill each feed line with grease before connecting lines to the injector outlets and bearings. This will prevent having to cycle the individual injectors once for each 25 mm (1 in.) length of feed line between the injector and bearing fitting. System Checkout While the engine is running, and/or accumulators are charged, exercise extreme care while working in the vicinity of the grease pump!
To check system operation (not including timer), pro- ceed as follows: Steering pressure is also available at this time. Keep personnel away from front wheels to pre- vent crushing! 1. Turn keyswitch (3, Figure 42-7) OFF and shut down the engine to de-energize the system. Install a 35 MPa (5000 psi) pressure test gauge in grease supply line (13, Figure 42-1). Stay clear of moving engine parts and do not loosen/disconnect any pressure fittings or hoses. 2. Turn keyswitch ON and start engine to energize the system. To set the Pressure Reducing Valve: 3. Lift the passenger seat, and connect a jumper wire between the SOL and LUBE SW terminals on the 24 VDC solid state lube timer.
The pump should begin to operate. 1. With keyswitch OFF, engine stopped, and steering accumulator pressure bled down, install a 35 MPa (5000 psi) pressure test gauge in the grease supply line (13, Figure 42-1). NOTE: If terminal post identification on the solid state timer is not legible, refer to Figure 42-7 for terminal identification. 2. At the truck hydraulic bleeddown manifold, dis- connect the bleeddown solenoid. (This will pre- vent the accumulators from bleeding down when the engine is shut down, later in Step 4.) 4. Keep the jumper wire connected until the pump stalls. 3. Start the truck engine.
When steering and brake pressures have stabilized, pull the retarder lever to the fully applied position to apply the brakes. 5. Observe the 35 MPa (5000 psi) pressure test gauge in the grease supply line. Pressure should be 17.2 - 20.7 MPa (2500 - 3000 psi). ! WARNING !: DO NOT exceed maximum pump pressure of 24.1 MPa (3500 psi). Exceeding this value will damage components and/or cause components to rupture, resulting in possible serious injury to any nearby personnel. 4. Turn keyswitch OFF to stop the engine. Then return the keyswitch to the ON position. 5. Lift the passenger seat, and connect a jumper wire between the SOL and LUBE SW terminals on the 24 VDC solid state lube timer.
The pump should operate. Keep the jumper wire con- nected until the pump stalls. If the pressure is not correct, adjust the pressure reducing valve as necessary (refer to Pressure Reducer Adjustment). NOTE: DO NOT exceed 2.1 MPa (300 psi) on cylinder pressure gauge (2, Figure 42-1) 6. Disconnect the jumper wire. The system should vent. 7. Turn the keyswitch OFF and shut down the engine to de-energize the system. Remove the 35 MPa (5000 psi) pressure test gauge previ- ously installed. Connect system components.