FRAME AS 3630140 - Caterpillar

Illustration 4 g06055026
Example of gage installation
Install two manometers with a minimum of 250 bar (3625 psi) one to each grease outlet at "A" and "B". Use two T-couplings installed in line with primary grease lines "A" and "B".
Illustration 5 g06055034
Check pump motor for operation.If, the pump motor is working, continue on to next step. If pump motor is not functioning check for the following:
Check ignition switch is in Off position / Turn switch to ON.
Broken Fuse / Exchange fuse.
Check for voltage at connector pins 1 and 2 on harness plug / Restore contact lock clips.
Check for damaged wiring / Restore wiring.
Check for power at the input connector on the controller board / Restore power connection.
Check Pump motor circuit is plug loose or disconnected from controller board / Reconnect.
Motor circuit broken or shows sign of short circuit / Exchange pump.
Controller board appears corroded or broken / Exchange controlled board.
Illustration 6 g06055105
Examples of bad and proper grease flow form the pump
Does The system have sufficient pressure? If the system does not have sufficient pressure Check for the following:
Air pockets in the pump / Fill reservoir and run pump until solid stream of grease appears with no air pockets
5/2 valve stuck in between outlets "A" and "B", pump runs heavily / Exchange Pump
Pump output at pump less than 220 bar (3190 psi) / Exchange pump
Pump should hold pressure of 180 bar (2610 psi) for 1 minute/ Check Grease filter for cracks / exchange filter /exchange pump
Illustration 7 g06055554
Locations of possible Internal system leaks
(1) First check at pump indicating internal leakage
(2) Second check past block one indicating problem further ahead
(3) Third check past block two indicating problem in block two
(4) Interior leakage between both lines due to missing bottom O-ring
Does system have internal leakage? / How to check?
Reconnect one system hose to pump outlet "A"and leave other hose disconnected
Start the pump. When grease keeps running from the loose hose (1) this situation indicates leakage in one of the distribution blocks in the system. A small amount of grease discharge is normal.
Locate the leaking distribution block / How ?
To locate the leaking block, the above described "check" procedure needs to be repeated after disconnecting the A-hose, just past the first distribution block. Refer to illustration 7.
When grease still flows from system hose ahead (2), repeat procedure with the next block in line (3).
Keep repeating procedure until leaking block is located (4).
Illustration 8 g06055659
Location of possible missing O-ring
Is the bottom O-ring injector / metering unit missing or damaged ?/ Replace with new O-rings.
Single bearing extremely over greased? / Check O-ring / Replace O-ring or metering unit that serves that point.
Leakage inside distribution block / Exchange distribution block.
Illustration 9 g06055668
5/2– way valve connection to the controller board
Pressure Relief?
Does the pump relieve the build-up pressure to the reservoir when activating the integrated 5/2-way valve?
Check connection at valve coil circuit / Valve cable disconnected? / restore connection at solenoid or controller board.
Broken circuit in valve coil? / Exchange pump
Shorted circuit in valve coil? / Exchange pump
Controller board corroded? / Exchange pump.
Controller board broken?