Komatsu 830E Shop Manual page 743

Preventative Maintenance Procedures
The following maintenance procedures should be
used to insure proper system operation.
Daily Lubrication System Inspection
1. Check grease reservoir level.
Inspect grease level height after each shift of
operation. Grease usage should be consistent
from day-to-day operations.
Lack of lubricant usage would indicate an
inoperative system. Excessive usage would
indicate a broken supply line.
2. Check filter bypass indicator when filling reser-
voir. Replace element if bypassing.
3. Check all grease feed line hoses from the SL-1
Injectors to the lubrication points.
a. Repair or replace all damaged feed line
hoses.
b. Make sure that all air is purged and all new
feed line hoses are filled with grease before
sending the truck back into service.
4. Inspect key lubrication points for a bead of lubri-
cant around seal. If a lubrication point appears
dry, troubleshoot and repair problem.
250 Hour Inspection
1. Check all grease feed line hoses from the SL-1
Injectors to the lubrication points (see, Figure 3-
2).
a. Repair or replace all worn / broken feed line
hoses.
b. Make sure that all air is purged and all new
feed line hoses are filled with grease before
sending the truck back into service.
2. Check all grease supply line hoses from the
pump to the SL-1 injectors.
a. Repair or replace all worn / broken supply
lines.
b. Make sure that all air is purged and all new
supply line hoses are filled with grease
before sending the truck back into service.
3. Check grease reservoir level.
a. Fill reservoir if low.
b. Check reservoir for contaminants. Clean, if
required.
c. Check that all filler plugs, covers and
breather vents on the reservoir are intact and
free of contaminants.
P03022
4. Inspect all bearing points for a bead of lubricant
around the bearing seal.
It is good practice to manually lube each bear-
ing point at the grease fitting provided on each
Injector. This will indicate if there are any frozen
or plugged bearings, and will help flush the
bearings of contaminants.
5. System Checkout
a. Remove all SL-1 injector cover caps to allow
b. Start truck engine.
c. Lift the passenger seat and connect a
d. Keep the system activated until the pump
e. With the pump in the stalled-out mode,
f. Once all of the SL-1 injectors have been
g. With the system vented, check all of the SL-1
h. Reinstall all injector cover caps.
i. Check timer operation.
Note: With engine running, lube system should
activate within 5 minutes. The system should build
2000 to 2500 psi within 25-40 seconds.
j. If the system is working properly, the
k. If the system is malfunctioning, refer to the
1000 Hour Inspection
1. Check pump housing oil level.
Automatic Lubrication System
visual inspection of the injector cycle indica-
tor pins during system operation.
jumper wire between "SOL" and "LUBE SW"
on the lube cycle timer or activate test switch
if installed. The hydraulic grease pump
should operate.
stalls out or the pressure switch closes.
check each SL-1 injector assembly. The
cycle indicator pin should be retracted inside
the injector body.
inspected under pressure remove the jumper
wire between the "SOL" terminal and "LUBE
SW" terminal on the timer assembly or open
test switch. The pump should shut off and
the pressure in the system should drop to
zero, venting back to the grease reservoir.
injector indicator pins; all of the pins should
be visible. Replace or repair injectors, if
defective.
machine is ready for operation.
troubleshooting chart.
P3-17