OM4021.2 8/00 Maintenance - Section 4 Automatic Lube System Page 4-27 Preventive Maintenance Procedures The following maintenance procedures should be used to insure proper system operation. Daily Lubrication System Inspection 1. Check grease reservoir level. 4. Inspect all bearing points for a bead of lubricant around the bearing seal. Inspect grease level height after each shift of operation. Grease usage should be consistent from day-to-day operations. It is good practice to manually lube each bearing point at the grease fitting (Zerk, Figure 4-8) pro- vided on each Injector. This will indicate if there are any frozen or plugged bearings, and will help flush the bearings of contaminants.
Lack of lubricant usage would indicate an inoperative system. Excessive usage would indicate a broken sup- ply line. 5. System Checkout 2. Check all grease feed lines hoses from the SL-1 Injectors to the lubrication points (Figure 4-6). a. Remove all SL-1 injector cover caps to allow visual inspection of the injector cycle indicator pins during system operation. a. Repair or replace all worn / broken feed line hoses. b. Lift the passenger seat and connect a jumper wire between the “SOL” terminal and the “LUBE SW” terminal on the 24VDC solid state timer (Figure 4-11). 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. c. Start engine. The hydraulic grease pump should operate. 3. Inspect key lubrication points for a bead of lubri- cant around seal. Make note of all lubrication points that look dry. Notify maintenance staff for repair service. d. Keep the jumper wire connected until the pump stalls out at 2000 PSI. e. With the pump in the stalled-out mode, check each SL-1 injector assembly. The cycle indicator pin should be retracted inside the injector body. 250 Hour Inspection 1. Check all grease feed line hoses from the SL-1 Injectors to the lubrication points (Figure 4-6). a.
Repair or replace all worn / broken feed line hoses. f. Once all of the SL-1 injectors have been in- spected under pressure, remove the jumper wire between the “SOL” terminal and “LUBE SW” terminal on the timer assembly. The pump should shut off, and the system should vent back to the grease reservoir, and the pressure should drop to zero. 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. 2. Check all grease supply line hoses from the pump to the SL-1 injectors. g. With the system vented, check all of the SL-1 injector indicator pins. All of the pins should be visible. a.
Repair or replace all worn / broken supply lines. 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. NOTE: Refer to the system troubleshooting chart, if the injectors are not working properly. Replace or repair injectors, if defective . 3. Check grease reservoir level. h. Reinstall all injector cover caps. a. Fill reservoir if low. b. Check reservoir for contaminants. Clean, if required. i. Check timer operation. With engine running, lube system should acti- vate within 5 minutes. The system should build 2000 PSI within 25-40 seconds. c.
Check that all filler plugs, covers and breather vents on the reservoir are intact and free of contaminants. j. If the system is working properly, the machine is ready for operation. k.If the system is malfunctioning, refer to the trou- bleshooting chart in the service manual.