System Operation - Komatsu 530M Operation & Maintenance Manual

Maintenance - Section 4
Page 4-16

System Operation:

1. During truck operation, with the pump and timer
systems in a rest state, a preset time interval (2.5
to 80 minutes) occurs.
2. The solid state system timer sends out a 24 VDC
signal to energize SV1, and also the flasher timer
on SV2.
3. As SVI opens, the hydraulic fluid pressure flows
through the pressure reducing valve and on to
SV2.
4. The pressure reducing valve lowers hydraulic fluid
pressure to the operating range of the hydraulic
pump [maximum pressure 300 p.s.i. (2069 kPa)].
This pressure also signals the Vent Valve causing
it to close.
5. After the system pressure has been reduced, it
passes on to SV2. Each operation of SV2 moves
the hydraulic cylinder which operates the grease
pump. As SV2 turns ''On'' and ''Off'' (refer to cycle
timer/flasher below), it changes the direction of
the hydraulic cylinder movement back and forth,
thus causing a ''pumping'' action.
6. The cycle timer/flasher sends a pulsing signal, 1
second ''On'' and 1 second ''Off'' (adjustable), to
SV2. Solenoid valve SV2 directs the hydraulic fluid
to the pump at 30 cycles/minute.
7. With the vent valve closed, the pump cycles until
lubricant pressure reaches maximum pump out-
put pressure* (pump stalls). As the grease supply
line comes to maximum pressure, the injectors
meter grease to the points of lubrication.
* WARNING: Maximum Pump Pressure Not to
Exceed 3500 p.s.i. (24.1 MPa). Exceeding this
value will damage components and/or cause
components to rupture, resulting in possible
serious injury to any nearby personnel.
8. After approximately 75 seconds, the Solid State
System Timer returns to the rest state, which
de-energizes SV1 solenoid valve.
9. As SV1 is de-energized, the hydraulic supply to the
pressure reducing valve and the vent valve is shut
off, causing the vent valve to open.
10. When the vent valve opens, the pressure in the
grease line is vented back to the grease reservoir
and the line pressure drops to zero (0), so the
injectors can recharge for their next output cycle.
11. The system is now at rest, ready for another lube
cycle and the sequence repeats itself.
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 Maximum Pump Pressure
of 3500 p.s.i. (24.1 MPa).
* Do not alter or modify any part of this system
unless approved by factory authorization.
* Do not attempt to repair or disassemble the
equipment while the system is pressurized.
* Make sure all fluid connections are securely
tightened before using this equipment.
* Always read and follow the fluid manufacturer's
recommendations regarding fluid compatibil-
ity, and the use of protective clothing and
equipment.
* Check all equipment regularly and repair, or
replace, worn or damaged parts immediately.
This equipment generates very high grease pres-
sure. Extreme caution should 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. Ade-
quate protection is recommended to prevent
splashing of material onto the skin or into the eyes.
If any fluid appears to penetrate the skin, get emer-
gency medical care immediately! Do not treat as a
simple cut. Tell attending physician exactly what
fluid was injected.
If overpressurizing of the equipment is believed to have
occurred, contact a factory authorized warranty and
service center for inspection of the pump. Specialized
equipment and knowledge is required for repair of the
pump or adjustments other than the maintenance
specified in this manual.
Annual inspection by the factory authorized warranty
and service center is recommended.
OM4006.2 10/98
Automatic Lube System