Komatsu 830E-AC, Shop Manual

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P03030 Automatic Lubrication System P3-3
AUTOMATIC LUBRICATION SYSTEM
GENERAL DESCRIPTION
The automatic lubrication system is a pressurized
lubricant delivery system which delivers a controlled
amount of lubricant to designated lube points. The
system is controlled by an electronic timer which sig-
nals a solenoid valve to operate a hydraulic motor
powered grease pump. Hydraulic oil for pump opera-
tion is supplied by the truck steering circuit.
Grease output is proportional to the hydraulic motor
input flow. A pump control manifold, mounted on top
of the hydraulic motor, controls input flow and pres-
sure. A 24VDC Solenoid mounted on the manifold
turns the pump on and off.
The pump is driven by the rotary motion of the
hydraulic motor, which is then converted to recipro-
cating motion through an eccentric crank mecha-
nism. The reciprocating action causes the pump
cylinder to move up and down. The pump is a posi-
tive displacement, double-acting type as grease out-
put occurs on both the up and the down stroke.
During the down stroke, the pump cylinder is
extended into the grease. Through the combination
of shovel action and vacuum generated in the pump
cylinder chamber, the grease is forced into the pump
cylinder. Simultaneously, grease is discharged
through the outlet of the pump. The volume of grease
during intake is twice the amount of grease output
during one cycle. During the upstroke, the inlet check
valve closes. One half the grease taken in during the
previous stroke is transferred through the outlet
check and discharged to the outlet port.
Over-pressurizing of the system, modifying
parts, using incompatible chemicals and fluids,
or using worn or damaged parts, may result in
equipment damage and/or serious personal
injury.
• DO NOT exceed the stated maximum
working pressure of the pump, or of the
lowest rated component in the system.
• Do not alter or modify any part of this sys-
tem unless approved by the factory.
• Do not attempt to repair or disassemble
the equipment while the system is pres-
surized.
• Make sure all fluid connections are
securely tightened before using this
equipment.
• Always read and follow the fluid manufac-
turer's recommendations regarding fluid
compatibility, and the use of protective
clothing and equipment.
• Check all equipment regularly and repair,
or replace, worn or damaged parts imme-
diately.
This equipment generates very high grease pres-
sure. Extreme caution must be used when oper-
ating this equipment as material leaks from loose
or ruptured components can inject fluid through
the skin and into the body causing serious bodily
injury including possible need for amputation.
Adequate protection is recommended to prevent
splashing of material onto skin or into the eyes.
If any fluid appears to penetrate the skin, get
emergency medical care immediately! Do not
treat as a simple cut. Tell attending physician
exactly what fluid was injected.
FIGURE 3-1. PUMP & RESERVOIR COMPONENTS
1. Hose From Filter
2. Outlet to Injectors
3. Hydraulic Motor
4. Pressure Reducing
Valve
5. Solenoid Valve
6. Test Switch
7. Vent Valve
8. Pressure Gauge
9. Pump Assembly
10. Flow Control Valve
11. Pressure Switch
12. Grease Reservoir
13. Vent Hose