service repair manual

2. EH1600/EH1700 GENERAL SERVICE INFORMATION
FORM/PUBLICATION NO.
GROUP TITLE
PUBLICATION NO. 10192 ENG
GROUP 0
11/01
091 Service Position and Safety SM638R1 SM638R1
Instructions
360ND 350HD

3. SERVICE POSITION AND SAFETY INSTRUCTIONS
GROUP 091
Page 1
Form SM638R1
SERVICE POSITION
Before working on the machine, park it on a level surface and put it in the “SERVICE POSITION”
1. Engine stopped, ignition key removed
(except when service requires engine
operation).
2. Tag the machine following local lockout &
tag procedure. Identify machine as ”Out
of Service”.
3. If body is raised, use body prop cable.
4. The Wheels blocked.
5. Body control lever in the “FLOAT”
position.
6. Parking brake applied.
7. Allow the machine to cool down.
8. Pressure released from all lines,
tanks, and accumulators.
WARNING!
If work must be done on a warm machine, beware of hot fluids and components.

4. GROUP 091
Page 2
SERVICE POSITION AND SAFETY INSTRUCTIONS
Form SM638R1
A FEW SIMPLE RULES WHEN SERVICING
TS41154
Do not perform any work on the machine unless you are
authorized to do so.
Maintenance can be dangerous unless performed properly. Be
satisfied that you have the necessary skills, information, correct
tools, and equipment to do the job correctly.
Standard maintenance procedures should always be observed.
Read the manufacturer’s manual or find assistance if you do not
understand what you are doing.
Failure to perform the Basic Preventive Maintenance as
outlined may void machine warranty.
Read all nameplates and decals before you operate the
machine. Each nameplate and decal has important information
about operation or service.
Deflate tires before loosening any rim clamp bolts.
Always stop the engine before removing inspection covers. Do
not let tools or parts fall into the opening.
Stand away from the rear exhaust area when the engine is
running.
When running a machine indoors, be sure the building is
properly ventilated.
WARNING!
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects and
other reproductive harm.
EL13914
Do not wear loose fitting clothing or jewelry when working on a
machine.
Always wear a hard hat, safety glasses, gloves, shoes or other
protective articles as the job requires.
Before you work on the machine always lower the body. If you
must work on the machine with the body raised, always securely
support the body using the body prop cable.
Be sure the machine is in the “SERVICE POSITION” before
lifting the machine. Always support an elevated machine using
proper blocks and/or cribbing before beginning work on it.
Be sure the “body prop cable” is engaged when working
beneath a raised dump body.

5. SERVICE POSITION AND SAFETY INSTRUCTIONS
GROUP 091
Page 3
Form SM638R1
A FEW SIMPLE RULES WHEN SERVICING
(continued)
V50387
When lifting or supporting components, use equipment with a
weight capacity as great or greater than the weight of the
component.
Use the correct tool(s) for the job. Repair or replace any broken
or defective equipment or tools.
Make sure that no tool(s) or other object(s) are left inside the
machine where they may cause damage.
Release all system pressure slowly before working on any part
of the hydraulic system.
EL13917
Remove all pressure caps carefully.
Be careful of hot fluid when changing oil in the engine, hydraulic
system, etc.
To find leakage, use a piece of cardboard or wood, not your
hand.
Never adjust a pressure relief valve above the manufacturer’s
recommendations.
Always inspect the cooling system with the engine stopped.
TS21481
Check that there is no damage to electric wires and hoses.
Check that there is no damage to hydraulic and brake hoses
caused by chafing. When wires have been disconnected it is
important that they are clamped so they cannot be exposed to
chafing.
When performing any welding operation on a machine, turn the
battery disconnect switch to the “OFF” position and disconnect
the negative (–) and positive (+) wire connections at the battery.
When welding and cutting, the paint must be removed up to a
distance of 10 cm (4 in) from the welding or cutting point. Paint
which is subject to high temperature may cause harmful gases.
The following safety instructions should be followed:
Remove the paint from the area where work is to be per-
formed through sand blasting.
If the paint cannot be removed by sand blasting, it must be
removed in some other way e.g., with paint stripper.

6. GROUP 091
Page 4
SERVICE POSITION AND SAFETY INSTRUCTIONS
Form SM638R1
A FEW SIMPLE RULES WHEN SERVICING
(continued)
Note: When using paint stripper, be sure to wear protective
gloves and work in a well ventilated area.
Note: A high speed grinding machine also heats the paint and
must only be used in a well ventilated area.
Polymer materials such as rubber and certain kinds of plastics
can, when heated, give off gases that may be dangerous to
health and environment.
The following safety instructions should be followed:
Do not weld or cut near polymer materials without first hav-
ing protected them from the heat.
Never burn polymer materials when scrapping them.
EL18558
Note: All steps, ladders, stairways, handholds, platforms,
walkways, and guard rails must be free of dirt, snow, and
ice.
Note: All steps, ladders, stairways, platforms, walkways, and
non–skid deck strips must be replaced if damaged.
FIRE PREVENTION MEASURES
Fire prevention features provided by the manufacturer should
be maintained in operational condition and should be used to
supplement operator’s fire prevention efforts. In no case should
the features be used or assumed as replacement for diligent
operator efforts at preventing fires.
Keep the work place clean. Oil or water on the floor makes it
slippery and dangerous in connection with electrical equipment
or electrically powered tools. Oily clothes are a serious fire
hazard.
Keep the machine and all equipment free of dirt and oil. This will
decrease possible fire hazards and make it easier to find loose
or defective parts. This is especially important when working
with combustible materials.
Machines should be clean of debris particularly around the
engine, exhaust, and drive shaft components. Keep the
machine extra clean when working in a sensitive environment.
Note: If a high pressure jet is used for cleaning, take great care as
the insulation of electrical wires can become damaged
even at moderately high pressure and temperature.
Protect electrical wires in a suitable way.

7. SERVICE POSITION AND SAFETY INSTRUCTIONS
GROUP 091
Page 5
Form SM638R1
FIRE PREVENTION MEASURES (continued)
Gasoline is highly flammable and should never be used as a
cleaning fluid. Use an approved solvent for cleaning.
Some solvents can cause skin rashes and or fire dangers. Do
not inhale solvent vapors.
Store flammable starting aids in a cool, well ventilated location.
V50389A
Smoking, open flames, etc., should not be permitted around any
machine during fueling operations and/or when the fuel system
is open to the atmosphere.
Prior to welding or brazing on any part of the machine, the part
and the surrounding area should be cleaned and a fire
extinguisher should be made readily available.
Hydraulic fluid is flammable. Do not weld on pipes or tubes that
are filled with fluid. Be careful when welding next to filled pipes or
tubes.
There is always a risk of fire. Find out which type of fire
extinguisher to use, where it is and how to use it.
In case of fire be prepared to run for safety, but if time permits
first:
Lower the body to the ground.
Stop the engine by turning the master key switch to the
”OFF” position.
Start combating the fire and/or call for help.
WASTE HAZARDOUS TO THE ENVIRONMENT
Waste fluids, components such as batteries, plastic objects and others
which might constitute an environment danger, should not just be thrown
away, but taken care of in a correct way in order to protect the
environment.
Note: Disposal of used lubricants, filters and batteries should be
done in accordance with the rules and regulations of the
local governing agencies.

8. EH1600/EH1700 SERVICE AND OPERATOR’S INDEX
FORM/PUBLICATION NO.
GROUP TITLE
GROUP 1
161 Automatic Centalized Lubrication SM754R2 SM754R2
161 Centralized Lubrication SM789 SM789
170 Machine Specifications SM878R1 SM878R1
179 Special Tools SM401R5 SM401R5
11/01 PUBLICATION NO. 10192 ENG
360ND 350HD

9. AUTOMATIC CENTRALIZED LUBRICATION SYSTEM
GROUP 161
Page 1
Form SM754R2
EL19177
Figure 1 -Lincoln Centralized Lubrication System, Single Line Parallel
1. Electric Pump Station 4. Right Front Injectors
2. Timer 5. Left Rear Injectors
3. Right Front Injectors 6. Right Rear Injectors
DESCRIPTION
Numbers in parentheses refer to Figure 1.
The Lincoln Centralized Lubrication System provides
a systematic method of lubricating a machine. While
the machine is in motion, the lubricant is automatically
delivered in time controlled and metered quantities to
all connected lube points in the system. The major
components of the system are: the electric pump sta-
tion (1), the timer (2), and the injectors (3, 4, 5, 6 & 7)
that direct lubricant to the various components on the
machine. Typical wiring of this system is shown in Fig-
ure 2.

10. AUTOMATIC CENTRALIZED LUBRICATION SYSTEM
GROUP 161
Page 2
Form SM754R2
EL19176
Figure 2 -Lincoln Centralized Lubrication System, Model View
1. Electric Pump Station 4. Right Front Injectors
2. Timer 5. Left Rear Injectors
3. Right Front Injectors 6. Right Rear Injectors
OPERATION
Numbers in parentheses refer to Figure 1.
In a single line, parallel system, a lubricant source
supplies lubricant flow through a single supply line at-
tached to each injector manifold. The individual injec-
tors of the injector manifold are “in line”, that is, the
source is directly connected to each injector at all
times. Each injector is operated simultaneously by
the lubricant flow and each injector operates indepen-
dently of the others in the system. The movement or
cycling of the individual injectors are therefore in
parallel to one another.
As previously stated, the injectors cycle independent-
ly of one another. Should an injector be unable to
cycle, the cycling of all the other injectors in the
system carries on normally. Lubricant flow will
be stopped only in the injector which is not cycl-
ing.
This system can be described as a measuring sys-
tem. The source provides lubricant to the system and
in each injector the rising pressure and the flow of lu-
bricant causes the injector to dispense and to mea-
sure lubricant. Once this portion of the cycle takes
place the injector is closed to lubricant flow; lubricant
flow is blocked and the system builds pressure. The

11. GROUP161
Page 3
AUTOMATIC CENTRALIZED LUBRICATION SYSTEM
Form SM754R2
system pressure rises to a preset maximum and the
supply of lubricant is stopped. The length of stroke,
which is adjustable, and the diameter of each mea-
suring piston in the injector determines how much lu-
bricant is displaced during each cycle of that injector.
Therefore the total lubricant flow from the source is
not delivered beyond the injector; only the volume
measured by each injector.
The injectors of the system are reset when the lubri-
cant pressure in the supply line is relieved or vented
back through the source to the reservoir. It is very im-
portant to understand that the lubricant supply
side of the system has to complete a cycle; first
providing lubricant and having that supplied lu-
bricant build to a preset pressure, and then re-
moving the lubricant supply and allowing the
supply pressure to fall back to zero.
EL19178
Figure 3 - Typical Electrical Wiring, Centralized Lube System

12. AUTOMATIC CENTRALIZED LUBRICATION SYSTEM
GROUP 161
Page 4
Form SM754R2
EL19195
Figure 4 -Timer (12/24 VDC)
TIMER 12/24 VDC
The timer is a 12 or 24 volt DC powered lubrication
system cycle timer. It has a fixed ”on-time” of 1.25
minutes, and a selectable ”off-time” (interval be-
tween cycles) of 2.5, 5,10, 20, 40, or 80 minutes.
During the 1.25 minute ”on-time,” an air solenoid or
other suitable device connected between the SOL
terminal and ground will be energized, and an internal
red LED will light.
SL1 INJECTOR
Each Lincoln ”Centro-Matic” SL1 injector assembly
contains from one to five injectors mounted on a man-
ifold. It is designed to inject grease to bearings with an
output pressure of up to 24131 kPa (3,500 psi).
Each manifold contains; the supply line connection
ports at either end, the mounting surface for the indi-
vidual injectors, flow passages to interconnect the in-
jectors and connection ports, and the mounting holes
to fix the manifold to the machine.
The injector is attached to its manifold by an adapter
bolt and is sealed by copper gaskets. Individual in-
jectors can be removed from the manifold for re-
pair or replacement without disturbing the other
injectors or the supply lines by turning out the
adapter bolt and disconnecting the feed line from the
injector outlet port.
The indicator stem is directly connected to the in-
jector piston and provides a visual indication of
the injector operation. When the supply system
pressure increases, the indicator stem moves into the
injector body and when the supply side relieves pres-
sure the indicator stem moves back out to rest against
the adjusting screw.

13. GROUP161
Page 5
AUTOMATIC CENTRALIZED LUBRICATION SYSTEM
Form SM754R2
The adjusting screw allows you to externally ad-
just the lubricant output of each individual injec-
tor. For the SL1 injector, the adjustment range is from
.008 to 0.08 cubic inches. As stated earlier the ad-
justment of one injector does not affect any other
injector output in the system. The injector assem-
bly can be mounted in any position with no effect on its
operating efficiency.
Under the cover cap of the fitting assembly is a grease
fitting which is directly connected to the discharge
chamber of the injector. By connecting a manual or air
powered grease gun you can inject grease directly
into the bearing through its feed line without dis-
turbing the lines or the functioning of the system.
If a component of the overall machine is removed and
the lubrication of that component is no longer required
the portion of the Centro-Matic system not used
can be plugged without any effect to the other in-
jectors of the system. If it is a single bearing point,
then the output port can be plugged with a plug. If it is
a leg of the supply side, then the end of the operating
supply side is plugged after the unused portion is dis-
connected.
EL18562
Figure 5 -SL1 Injector Assembly
1. Manifold 7. Adjusting Screw 13. Outlet Port(1/8 NPTF)
2. Mounting Hole 8. Adjusting Screw Locknut 14. Plunger Spring
3. Adapter Bolt 9. Measuring Chamber 15. Slide Valve
4. Injector 10. Injector Piston 16. Passage
5. Cover Cap, Metal 11. Discharge Chamber 17. Gasket
6. Indicator Stem 12. Fitting Assembly

14. AUTOMATIC CENTRALIZED LUBRICATION SYSTEM
GROUP 161
Page 6
Form SM754R2
EL191
Figure 6 - SL1 Injector Cutaway

15. GROUP161
Page 7
AUTOMATIC CENTRALIZED LUBRICATION SYSTEM
Form SM754R2
SYSTEM MALFUNCTIONS
MALFUNCTION SYMPTOM CAUSE SOLUTION
Pump does not
discharge lubricant.
Little or no pressure
at the gauge.
Empty reservoir.
Loss of power to
pump.
Air trapped within
the pump element.
Pump damaged
internally.
Loss of hydraulic
pressure
Fill
Check fuse.
Check electrical connec-
tions.
Check timer.
Disconnect the outlet line
and cycle the pump to
purge.
Replace.
Excessive system
pressure. See trou-
bleshooting chart.
Bearing not receiv-
ing lubricant. Sys-
tem is operating
and lubricant is be-
ing dispensed.
High pressure at gauge.
Dry bearing.
Blocked injector.
Blocked or crushed
line.
Blocked bearing inlet.
Tight bearing.
Broken line.
Leakage at fitting.
Remove metering valve
and clean. Check piston
and bore for damage and
replace if necessary.
Replace.
Clean out material.
New pin and bush-
ing may be too
tight. Modify grease
channel.
Check lines; replace
where necessary.
Tighten loose fit-
tings. Replace dam-
aged fittings.
Check system pressure

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17. AUTOMATIC CENTRALIZED LUBRICATION SYSTEM
GROUP 161
Page 8
Form SM754R2
Low level of grease or reservoir is empty. Refill reservoir.
CONDITION POSSIBLE CAUSE CORRECTIVE ACTION
Pump does not op-
erate
No hydraulic power to pump Turn on or connect hydraulic supply to
pump.
No pressure on gauge:
Closed supply line shut off valve.
No power to solenoid valve.
Faulty Solenoid.
Pressure Reducing Valve is set too low.
Insufficient Hydraulic Fluid supply
Open shut-off valve.
Correct electrical fault.
Replace solenoid.
Reset Pressure Reducing Valve.
Check hydraulic supply for proper
pressure and flow.
Pressure is shown on gauge on pump
manifold.
Closed fluid outlet line.
Flow Control Valve is fully closed.
Pump is stalled due to grease
backpressure.
Check outlet line and clear obstructions.
Readjust flow control valve to 1 turn open.
Check vent valve in system.
Pump is seized or damaged. Dismantel the pump and repair defec-
tive or seized component. See pump
service page.
Pump runs esces-
sively
Pump tube malfunction. Refer to pump service page.
Outlet check damage or contamination. Repair check or remove contamination.
Vent valve damage or contamination. Repair vent valve or remove
contamination.
System component leaking Repair leaks.
Vent valve not receiving proper pressure Orifice fitting plugged.
to keep it closed.
Injector bypassing. Repair injectors.
Pump speeds up or
runs erratically.
Follower plate is stuck and separated Check follower plate and container for
from grease. for damage.
Pump piston or checks are worn. Refer to pump service sheet.
Insufficient hydraulic fluid supply. Check hydraulic supply and adjust flow.
Pump runs, but out-
put is low.
Inlet pressure too low. Increase pressure at pressure control
valve.
Faulty inlet or discharge check valve in Replace faulty components. See pump
pump. service page.

18. GROUP161
Page 9
AUTOMATIC CENTRALIZED LUBRICATION SYSTEM
Form SM754R2
CONDITION POSSIBLE CAUSE CORRECTIVE ACTION
Lubricant leaking from Pressure of system set too high. Adjust pressure switch setting.
safety unloader valve. Safety unloader damaged or Replace safety unloader.
contanminated.
Lubricant leaking from Vent valve lubricant seal damaged. Replace lubricant seal.
weep hole in vent
valve.
INJECTOR
TROUBLE SHOOTING
Excessive lubricant Piston packing, plunger packing worn. Replace packing.
output.
Seepage of lubricant Piston stop packing worn. Replace packing.
at indicator stem.

19. CENTRALIZED LUBRICATION SYSTEM
(NON–AUTOMATIC)
GROUP 161
Page 1
Form SM789
EL19179
Figure 1 –Centralized Lubrication System
DESCRIPTION
The Centralized Lubrication System provides a sys-
tematic method of lubricating a machine by grouping
the necessary lube points into easily accessed man-
ifolds on the frame.