System Components - Komatsu 830E Shop Manual

SYSTEM COMPONENTS

Filter (21, Figure 3-2)
A filter assembly mounted on the grease reservoir fil-
ters the grease prior to refilling the reservoir from the
shop supply. A bypass indicator alerts service per-
sonnel when the filter requires replacement.
Hydraulic Motor and Pump (3 & 9, Figure 3-1)
Note: The pump crankcase oil level must be
maintained to the level of the pipe plug port. If
necessary, refill with 10W-30 motor oil.
Specifications are as follows:
Max. hydraulic oil inlet pressure:
. . . . . . . . . . . . . . . . . . . . . . . . 3,000 psi (20 685 kPa)
Hydraulic oil operating pressure:
. . . . . . . . . . . . . . . . . . 325-350 psi (2 240-2 415 kPa)
Hydraulic inlet flow
. . . . . . . . . . . . . . . . . . . . . . . up to 7 GPM (28 L/min.)
Pump ratio: approx. 9:1
. . @300 to 350 psi (2 068 to 2 415 kPa) oil pressure
. . . . . . . . . . . . . . . @less than 2 GPM (7 L/min.) flow
Operating temperature
. . . . . . . . . . . . . . . . . . -20 to +150° F (-10 to +65° C)
Hydraulic oil supply inlet pressure must not
exceed 3000 psi (20 685 kPa). Exceeding the
rated pressure may result in damage to the sys-
tem components and personal injury.
Grease Reservoir (12, Figure 3-1)
The reservoir has an approximate capacity of 90 lbs.
(41 kg) of grease. When the grease supply is replen-
ished by filling the system at the service center, the
grease is passed through the filter to remove con-
taminants before it flows into the reservoir.
Pressure Reducing Valve (4, Figure 3-1)
The pressure reducing valve, located on the manifold
reduces the hydraulic supply pressure (from the truck
steering circuit) to a suitable operating pressure,
[325-350 psi (2 240-2 415 kPa)] for the hydraulic
motor used to drive the lubricant pump.
Flow Control Valve (10, Figure 3-1)
The flow control valve mounted on the manifold, con-
trols the amount of oil flow to the hydraulic motor.
P03022
The flow control valve has been factory adjusted
and the setting should not be disturbed.
Solenoid Valve (5, Figure 3-1)
The solenoid valve, when energized, allows oil to
flow to the hydraulic motor.
Vent Valve (7, Figure 3-1)
With the vent valve closed, the pump continues to
operate until maximum grease pressure is achieved.
As this occurs, the vent valve opens and allows the
grease pressure to drop to 0, so the injectors can
recharge for their next output cycle.
24 VDC Lubrication Cycle Timer (Not Shown)
The lube cycle timer provides a 24 VDC timed-inter-
val signal to operate the solenoid valve (5, Figure 3-
1), causing the grease pump motor to operate. This
timer is mounted in the cab (in the housing under the
passenger seat) to insure temperature stability.
Pressure Switch (N.O. 2500 psi [17 237 kPa])(11,
Figure 3-1)
The pressure switch energizes the normally closed
pump solenoid relay when the grease line pressure
reaches the switch pressure setting, turning off the
motor and pump.
Unloader Valve (Not Shown)
The unloader valve is mounted on a "tee" fitting with
the pressure switch described above. This valve will
relieve grease pressure in the pump if pressure
exceeds 4000 psi (27.6 MPa). This valve has been
factory adjusted and is not repairable.
Pressure Gauge (8, Figure 3-1)
The pressure gauge monitors hydraulic oil pressure
to the inlet of the hydraulic motor.
Manual Override (6, Figure 3-1)
The manual override is used to actuate the hydraulic
motor to manually activate a lubrication cycle.
Injectors (23, Figure 3-2)
Each injector delivers a controlled amount of pres-
surized lubricant to a designated lube point. Refer to
Figure 3-2 for locations.
Pressure Switch (24, Figure 3-2)
This pressure switch will activate a Lube System Low
Pressure Warning lamp on the overhead display if
adequate grease pressure (2000 psi (13 790 kPa)) is
not attained within 1 minute.
Automatic Lubrication System P3-3