OM4006.2 10/98 Maintenance - Section 4 Automatic Lube System Page 4-17 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 reprime the system to eject all entrapped air. If pressure is not correct, adjust the Pressure Reducing Valve as necessary (refer to ‘‘Pressure Reducer Adjustment’’). NOTE: DO NOT EXCEED 300 PSI (2.1 MPa) on the Cylinder Pressure gauge (2, Figure 4-5) 1. Fill lube reservoir with lubricant, if necessary. 6. Disconnect jumper wire. System should vent. 2. Remove plugs from all injector manifold dead ends and supply lines. 7.
Turn Keyswitch ‘‘Off’’ and shut down engine to de-energize system. Remove the 5000 PSI (35 MPa) pressure test gauge previously installed. Re-connect system. NOTE: To run the grease pump when priming the lube system, turn keyswitch "ON" and connect a jumper wire between the "LUBE SW" and "SOL" terminals on the solid state timer . 3. Run grease pump until grease flows from any one plug opening in the system. Replace plug in this opening. Pressure Reducer Adjustment NOTE: Steering accumulator pressure is necessary to power the lube system for this procedure . 4. Repeat step 3 until all lines are full and all plugs replaced. NOTE:
Fill each feed line with grease before connect- ing lines to the injector outlets and bearings. This will prevent having to cycle the individual injectors once for each 1.0 in. (25 mm) length of feed line between the injector and bearing fitting . While engine is running, and/or accumulators are charged, exercise extreme care while working in the vicinity of the grease pump! Steering pressure is also available at this time. Keep personnel away from front wheels to prevent crushing! System Checkout To check system operation (not including timer), pro- ceed as follows: Stay clear of moving engine parts and do not loosen/disconnect any pressure fittings or hoses. 1.
Turn Keyswitch (3, Figure 4-11) ‘‘Off’’ and shut down engine to de-energize system. Install a 5000 PSI (35 MPa) pressure test gauge in the grease supply line (13, Figure 4-5). To set the Pressure Reducing Valve: 1. With keyswitch ‘‘Off’’, engine stopped, and steer- ing accumulator pressure bled down, install a 5000 PSI (35 MPa) pressure test gauge in the grease supply line (13, Figure 4-5). 2. Turn Keyswitch ‘‘On’’ and start engine to energize system. 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. Pump should operate. 2. At the truck Hydraulic Bleeddown Manifold, dis- connect the Bleeddown Solenoid.
(This will pre- vent accumulators from bleeding down when engine is shut down, later in step 4.) NOTE: If terminal post identification on the solid state timer is not legible, refer to Figure 4-11 for terminal positions . 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. 4. Keep jumper wire connected until the pump stalls. 5. Observe the 5000 PSI (35 MPa) pressure test gauge in the grease supply line. Pressure should be 2500 - 3000 PSI (17.2 - 20.7 MPa). 4. Turn keyswitch ‘‘Off’’ to completely stop 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. Pump should operate. Keep jumper wire con- nected until the pump stalls. ! WARNING !: DO NOT EXCEED Maximum Pump Pressure of 3500 p.s.i. (24.1 MPa). Exceeding this value will damage components and/or cause components to rupture, resulting in possible serious injury to any nearby personnel.