Professional Documents
Culture Documents
Maintenance Manual
AUTO GREASING
SYSTEM
HYDRAULIC EXCAVATOR
APPLICABLE MODELS
PC210-6K PC210-7K
PC240-6K PC240-7K
PC290-6K PC290-7K
PC340-6K PC340-7K
PC380-6K
PC600-6K
PC750-6K
WARNING
Unsafe use of this machine may cause serious injury or
death. Operators and maintenance personnel must read
this manual before operating or maintaining this
machine. This manual should be kept inside the cab for
reference and periodically reviewed by all personnel who
will come into contact with the machine.
CONTENTS
Troubleshooting .................................................................................................................................................. 20
Lubricants ............................................................................................................................................................ 24
Troubleshooting .................................................................................................................................................. 35
Lubricants ............................................................................................................................................................ 39
1
Applications ......................................................................................................................................................... 42
Mode of Operation ...................................................................................................................................... 42
Time Setting ................................................................................................................................................ 44
Operational Test / To Trigger an Additional Lubrication Cycle ................................................................... 46
Troubleshooting .................................................................................................................................................. 47
2
LUBRICATION SYSTEM
3
Safety Instructions LUBRICATION SYSTEM
Safety Instructions
CAUTION
Make sure that you are familiar with the operation and safety
instructions of the base machine as well as the operation
instructions for the Centralised Greasing System.
Appropriate Use
❍ authorized and
❍ instructed personnel
4
LUBRICATION SYSTEM Safety Instructions
Installation
When the push-in type fittings are used, note the following:
● For the metering device inlet use only push-in type fittings
with reinforced collar and sealing ring.
● For the outlet fittings of the main metering device use only
valve bodies with reinforced collar.
NOTE: Use high pressure plastic hoses for the lubricant feed
lines. The outlet fittings of the secondary metering
devices and the connection fittings to the lubricant points
must have a reinforced collet
● Use only high pressure plastic hoses and plastic tubes speci-
fied by KOMATSU and adhere to the specified system pres-
sures.
Printed-Circuit Board
Installation Instructions
Parts Catalog
5
Progressive Metering Devices Model SSV LUBRICATION SYSTEM
Suitable Lubricants
Fig.1 - SSV 8 metering device, shown as a demonstration model
REMARK
Ensure that the oils or greases used do not alter their consis-
tency in the course of time or under the influence of temperature
or pressure.
REMARK
To simplify the description we only show the lubricant distri-
bution for outlets 2, 7, 5, 3 and 1. The remaining distribution oper-
ations are derived from the logical pumping sequence.
6
LUBRICATION SYSTEM Progressive Metering Devices Model SSV
Phase 1
The lubricant enters the metering device from above (white arrow
above) and flows to the right-hand end of piston A.
Lubricant pressureless
Phase 2
Lubricant pressureless
7
Progressive Metering Devices Model SSV LUBRICATION SYSTEM
Phase 3
Lubricant pressureless
Phase 4
Lubricant pressureless
8
LUBRICATION SYSTEM Progressive Metering Devices Model SSV
Phase 5
Lubricant pressureless
System-dependent monitoring
9
Progressive Metering Devices Model SSV LUBRICATION SYSTEM
Visual monitoring
NOTICE
Important: In the case of the progressive metering devices
models SSV 6 - 12 and the block-type metering devices SSV
14 through SSV 22 the outlets 1 and/or 2 must never be
closed. In the case of the combined progressive metering
devices model SSV 14 - 22, the two outlets with the highest
numbers must never be closed, otherwise the system would
block owing to the structure of the metering device.
10
LUBRICATION SYSTEM Progressive Metering Devices Model SSV
NOTICE
Important ! For the system monitoring it is recommended
that one SSV metering device with pre-assembled piston
detector be used per lubrication circuit. These special
metering devices must be ordered separately for each lubri-
cation system. Refer to Parts Catalog.
11
Progressive Metering Devices Model SSV LUBRICATION SYSTEM
Fig. 11. Install the outlet and closure plugs in accordance with the
dosage
REMARK
Never use closure plug 3 (Fig. 11) as a piston closure plug (G
1/8) 4 on older models of metering devices.
12
LUBRICATION SYSTEM Progressive Metering Devices Model SSV
REMARK
In the case of the push-in type fittings and with the valve body
5 the clamping ring is a firm component part of the valve body
(see fig. 12, 13).
NOTICE
Important: In the case of the progressive metering devices
models SSV 6 - 12 and with the block-type metering devices
SSV 14 through SSV 22 the outlets engraved "1" and/or "2"
must never be closed. In the case of the combined progres-
sive metering devices model SSV 14 - 22, the two outlets with
the highest numbers must never be closed, otherwise the
system would be blocked.
Fig. 12 - Install the outlet push-in type fittings and the closure
plugs in accordance with the dosage
1. Inlet fitting with protective cap (on request) 5. Valve body assembly (with reinforced collar)
3. Closure plug (M 10 x 1) with copper washer 7. Closure plug (M 10 x 1) with hex. socket head and
installed in outlet borehole sealing edge, replaces pos. 3
13
Progressive Metering Devices Model SSV LUBRICATION SYSTEM
Fig. 13 - Install the push-in type outlets fittings and closure plugs
in accordance with the dosage
14
LUBRICATION SYSTEM Progressive Metering Devices Model SSV
● If a triple quantity is needed (at outlet 1), close the outlet bore-
hole located above the discharge borehole. Refer to outlets 3
and 5.
15
Progressive Metering Devices Model SSV LUBRICATION SYSTEM
Check valves
Metering Devices
NOTICE
Important ! For the inlet fittings use only tube fittings with
reinforced collar 1a (Fig. 17) and sealing ring 1b at the
thread.
Check valves
16
LUBRICATION SYSTEM Progressive Metering Devices Model SSV
REMARK
Use high pressure plastic hoses. The check valves of the sec-
ondary metering devices must have a reinforced collar and
smooth flange A.
2a knurled collar
Fig. 19: Check valve with reinforced collar and hose stud
NOTICE
Important! Connect only main lines (Ø 8.4 x 2.3 mm) with
threaded sleeve and hose studs to the inlet fitting and to the
check valves with reinforced collar.
Fig. 20: Check valve wirh knurled collar and pressure plastic tube
REMARK
Exceptionally the high-pressure plastic hose (Ø 8.6 x 2.3 mm)
with threaded sleeve and hose stud may also be used for the low-
pressure section. Use check valves and inlet fittings (towards the
lubrication point) with reinforced collar for the low-pressure range.
Refer to Parts Catalog.
● The pressure plastic tubes are marked with white lines (Fig.
20) as an installation aid.
● Cut the pressure plastic tube off at one of the white lines
before it is mounted. Then insert the plastic pressure tube into
the fitting up to the next white mark. This will ensure a correct
installation of the pressure plastic tube in the threaded tube
fitting.
17
Progressive Metering Devices Model SSV LUBRICATION SYSTEM
To prevent dirt from entering the system, the push-in type fittings,
check valves and safety valves can be equipped with protective
caps.
NOTICE
Important: Before screwing the parts 1 and 3, rub them with
oil.
18
LUBRICATION SYSTEM Progressive Metering Devices Model SSV
NOTE: When using the special adjusting gauge (see Pats Cata-
log) screw the threaded sleeve counterclockwise onto the
high-pressure plastic hose until the gauge inserted in the
sleeve begins to rise.
19
Troubleshooting LUBRICATION SYSTEM
Troubleshooting
Cause Correction
20
LUBRICATION SYSTEM Troubleshooting
Cause Correction
Cause Correction
● Setting of the pause time or operating time incor- ● Check the time setting. Refer to the corresponding
rect setting in the respective “Operating Instructions”.
Cause Correction
21
Technical Data LUBRICATION SYSTEM
Technical Data
Low-pressure range,
Outlet fittings, secondary metering devices p max. 250 bar
Inlet fittings to the lubrication point
Lines
22
LUBRICATION SYSTEM Tightening Torques
Tightening Torques
screw-type 17 Nm
push-in type 10 Nm
screw-type 10 Nm
push-in type 8 Nm
steel tube 10 Nm
23
Lubricants LUBRICATION SYSTEM
Lubricants
The lubrication pump can dispense greases up to NLGI grade 2
or mineral oils of at least 40 mm²/s (cST) at 40°C.
NOTICE
Important: Absolute cleanliness is essential when handling
lubricants. Impurities will remain suspended in the lubricant
and cannot settle. This will block the delivery channels, thus
causing damage to the bearings. Do not use lubricants with
solid matter additives.
Grease
Manufacturer (Lithium base)
NLGI No. 2
G2-LI
KOMATSU
G2-LI-S
AGIP GR MU/EP
Litholine HEP 2
ARCO
Arco EP moly D
BP Energrease LS-EP2
Gulfcrown EP2
GULF
EGulfcrown EP special
Mobilux EP2
MOBIL Mobilgrease 77
Mobilgrease special
24
LUBRICATION SYSTEM Lubricants
Grease
Manufacturer (Lithium base)
NLGI No. 2
Multifak EP2
TEXACO
Starplex 2
UNION Unoba EP
25
Lubricants LUBRICATION SYSTEM
26
Central Lubrication Pump
27
Safety Instructions Central Lubrication Pump
Safety Instructions
Appropriate Use
CAUTION
In the case of pumps which are filled from top, the voltage
supply must be switched off before the lubricant is filled in.
28
Central Lubrication Pump Safety Instructions
Installation
● Safety equipment
29
Central Lubrication Pump Central Lubrication Pump
pump element
safety valve
filling nipple
30
Central Lubrication Pump Central Lubrication Pump
Operation
● The electric motor drives an eccentric cam which moves the Fig. 2 - Pump element
piston (1) (Fig. 2).
NOTICE
Important! Each pump element must be protected by means Fig. 6 - Pressure relief valve
of a pressure relief valve.
Control Units
REMARK
The Operating Instruction describes the function of a pump Fig. 7 - p.c.b. integrated in housing
without control unit. For details about optional control unit please
refer to the respective Operating Instruction of the control unit.
Commissioning
31
Maintenance, Repair and Tests Central Lubrication Pump
Maintenance
NOTE: The opertion of the centralised lubrication system should
be checked every 50 - 100 hours, depending upon the
operating environment, at the operator’s discretion.
Severe damage may occur to the machine’s bearing sur-
faces if the machine is operated negligently.
REMARK
Whenever work is done on the centralised lubrication system,
particular attention should be given to absolute cleanliness. Dirt in
the system will cause problems.
To Fill Pump
Fill the reservoir via the filling fitting up to the “max.” mark.
NOTICE
Important: The grease/oil must be free from impurities and
must not be liable to change its consistency in the course of
time.
REMARK
If the reservoir has been completely emptied, the pump may
require approximately 10 minutes before it operates with its full
output again.
Repair
Pump
32
Central Lubrication Pump Maintenance, Repair and Tests
2. Unscrew the pump element. Take care thet the piston, the
pull-back spring and the washer are not left lying in the
grease, otherwise the reservoir must be disassembled in
order to remove these pieces.
CAUTION
Do not leave the piston, spring and washer in the housing
because they may block the motor.
Tests
REMARK
Each time an additional lubrication cycle is initiated, the pump
supplies grease or oil to the connected lubrication points.
33
Maintenance, Repair and Tests Central Lubrication Pump
Either
or
● Connect the hand pump of the pressure and function test set
to the safety valve and check the opening pressure with the
hand pump.
NOTICE
Important: Do not connect the pressure gauge directly to the
pump element. High pressure may exceed the a.m. range
causing a stalling of the motor. The motor is designed in
such a way that it can stall for about 30 minutes without
being damaged.
34
Central Lubrication Pump Troubleshooting
Troubleshooting
REMARK
The pump operation can be checked from the outside by
observing whether the stirring paddle is rotating (e.g. by triggering
an additional lubrication).
For faults with pumps with integrated control units please refer to
the respective Technical Description or the Operating Instructions
of the integrated printed circuit board.
Cause Remedy
● Check the line leading from the fuses to the pump plug.
Cause Remedy
35
Technical Data Central Lubrication Pump
Technical Data
Pump
Reservoir capacity 2 l, 4 l, 8 l
REMARK
The pump is suitable for the a.m. temperature range. The
lubricants used must still be pumpable at the temperatures men-
tioned above.In case of doubt, consult the manufacturer of the
lubrication system.
Motor:
12V 6.5 A
24V 3A
Piston diameter, K5 5 mm
Lubricant output approx. 2 cm³/min
36
Central Lubrication Pump Technical Data
Piston diameter, KR 7 mm
NOTICE
The lubricant output listed refers to grease of NLGI grade 2
measured at 20° C, back pressure 100 bar, nominal voltage
24 V. Any differing pressures or temperatures result in differ-
ent lubricant outputs.
37
Technical Data Central Lubrication Pump
Connection Diagram
C. line socket 1 with connection cable, 3-wire switching voltage max. 230 VAC
38
Central Lubrication Pump Lubricants
Lubricants
The pump has been designed to deliver commercial greases up
to NLGI grade 2 or mineral oils of at least 40 mm²/s (cSt) at 40° C.
NOTICE
Absolute cleanliness is essential when handling lubricants.
Impurities will remain suspended in the lubricant and cannot
settle. This will result in damage to the lubrication system
and thus to the bearings.
Grease
Manufacturer (Lithium base)
NLGI No. 2
G2-LI
KOMATSU
G2-LI-S
AGIP GR MU/EP
Litholine HEP 2
ARCO
Arco EP moly D
BP Energrease LS-EP2
MS3
CASTROL
Spheerol EPL2
Gulfcrown EP2
GULF
EGulfcrown EP special
Mobilux EP2
MOBIL Mobilgrease 77
Mobilgrease special
39
Lubricants Central Lubrication Pump
Grease
Manufacturer (Lithium base)
NLGI No. 2
Multifak EP2
TEXACO
Starplex 2
TOTAL Multis EP2
UNION Unoba EP
40
Printed Circuit Board
(standard system)
41
Applications Printed Circuit Board (standard system)
Applications
CAUTION
Do not connect the red core of the connecting cable to con- Fig. 1 - Machine contact, printed circuit board
nection 1, Fig. 1, 14, 16 (terminal 30) since terminal 30 is con-
nected internally with terminal 15.
When the driving switch (terminal 15) is switched on, the central-
ized lubrication system is ready for operation
When the driving switch (terminal 15) is switched on, the central-
ized lubrication system is ready for operation
Mode of Operation
● The printed circuit board is integrated in the pump housing. Fig. 3 - Printed circuit board installed in the
housing
● The printed circuit board automatically controls the sequence
of the pause and operating times of the central lubrication
pump as a function of the machine working hours tB (Fig. 5).
● A lubrication cycle consists of one pause time and one oper- Fig. 4 - Printed circuit board
ating time. Once the pause time has elapsed, the operating
time starts to run. This lubrication cycle is repeated perma-
nently after the machine has been put into operation. Refer to
Fig. 4.
42
Printed Circuit Board (standard system) Applications
❍ is adjustable.
❍ is adjustable;
Time storage
43
Applications Printed Circuit Board (standard system)
Time Setting
CAUTION
This centralised lubrication system has been set at the fac-
tory . Do not reduce the operating time or increase the pause
time from the factory setting without consulting Komatsu.
1. To set the pause or operating time, remove the cover on the Fig. 6 - The cover to access the printed cir-
pump housing. cuit board has been removed
REMARK
To reset a jumper (Fig. 8), remove the printed circuit board.
NOTICE
Important: After having set the pause time or operating time,
screw the cover on the pump housing again
The pause time can be set to 15 different settings by means of Fig. 7 - Rotary Switch Pause Time
the blue rotary switch.
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
Minutes 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60
Hours 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
REMARK
When the switch is on ”0” a fault is shown at the right-hand
LED 3.
At the same time the factory-set pause time is accepted.
Factory setting
or 24 minutes
44
Printed Circuit Board (standard system) Applications
● The operating time can be set to 15 different setting by Fig. 9 - Rotary switch - Operating time
means of the red rotary switch.
Switch position 1 2 3 4 5 6 7 8 9 A B C D E F
10 11 12
Minutes 8 16 24 32 40 48 56 64 72 80 88 96
4 2 0
Hours 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
REMARK
When the switch is on ”0” a fault is shown at the right-hand
LED 3 Fig. 11. At the same time the factory-set operating time is
accepted
Factory setting
or 24 seconds
Fault indication
45
Applications Printed Circuit Board (standard system)
● The motor of the pump also runs according to the flash fre-
quency.
Repair
NOTICE
Where an additional push button is fitted inside the cab (see
photograph), this button may be used to trigger an additional
lubrication cycle. Under automatic lubrication, the button
will illuminate when the pump is active. Please note that this
does not provide system fault indication.
46
Printed Circuit Board (standard system) Troubleshooting
Troubleshooting
REMARK
The pump operation can be checked from the outside by
observing whether the stirring paddle is rotating (e.g. by triggering
an additional lubrication), whether the LEDs on the printed circuit
board are lit.
Cause Remedy
● Voltage supply interrupted betweeen the printed ● Triggering an additional lubrication cycle
circuit board and the motor ● If the voltage is applied, the right-hand LED is lit.
Cause Remedy
● Short circuit at pushbutton 5 Fig. 12 or, if present, ● Check whether the short circuit is at the PCB or, if
at the illuminated push button or at their connecting present, at the illuminated pushbutton.
parts If necessary, exchange the PCB or the illuminated
Signal: 3 flashes pushbutton
47
Technical Data Printed Circuit Board (standard system)
Technical Data
Residual rippple in relation with the operating voltage ± 5% acc. to DIN 41755
Class of protection
All the printed circuit boards comply with the EMC (Electromag-
netic compatibility) guidelines for road vehicles acc. to DIN 40839
T1, 3 and 4 and the EMC guideline 89 / 336 / EWG
Time setting
4; 8; 12; 24 to 60 minutes
Pause time, depending on the jumper position:
1, 2, 3...to 15 hours
8; 16; 24;....to 120 seconds
Operating time, depending on the jumper position
2, 4, 6,....to 30 minutes
Factory setting
Pause time hours
or minutes
or seconds
48
Printed Circuit Board (standard system) Technical Data
Connection Diagram
DO NOT CONNECT
D -Line socket 1 (black) with con- O - Signal lamp in the case of low-
H - Cable, black
nection cable, 3-wire level control
CAUTION
Do not connect the red core (shown ref. J ) of the 3-core con-
necting cable to the wire box 1 (D) since the PCB is con-
nected internally between 30 and 15.
49
Technical Data Printed Circuit Board (standard system)
Possibilities of
Pause time ranges Operating time range
Preselection Jumper positions
See fig. 8, 10
Combination no. 4- 60 min 1 - 15 h 8 - 120 s 2 - 30 min
V 10, Standard X X
50
Printed Circuit Board (standard system) Technical Data
51