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Operation & UEAM001401

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

LUBRICATION SYSTEM ..................................................................................... 3


Safety Instructions ................................................................................................................................................ 4

Progressive Metering Devices Model SSV ......................................................................................................... 6


Suitable Lubricants ....................................................................................................................................... 6
Lubricant Distribution within the Metering Device ......................................................................................... 6
Monitoring of the Operation .......................................................................................................................... 9
Determining the Lubricant Output by Combining Outlets ............................................................................ 12
Tube Fittings, Plug-Type (secondary metering devices) ............................................................................. 14
Lubricant Metering Devices SSV 14 up to SSV 22 ..................................................................................... 15
Tube fittings, Screw-type ............................................................................................................................ 16
Tube Fittings, Push-in Type ........................................................................................................................ 16
Plastic tubes and high-pressure plastic hoses ............................................................................................ 18

Troubleshooting .................................................................................................................................................. 20

Technical Data ..................................................................................................................................................... 22

Tightening Torques ............................................................................................................................................. 23

Lubricants ............................................................................................................................................................ 24

Central Lubrication Pump ................................................................................ 27


Safety Instructions .............................................................................................................................................. 28

Central Lubrication Pump .................................................................................................................................. 30


Operation .................................................................................................................................................... 31

Maintenance, Repair and Tests ......................................................................................................................... 32


Maintenance ............................................................................................................................................... 32
Repair ......................................................................................................................................................... 32
Tests ........................................................................................................................................................... 33

Troubleshooting .................................................................................................................................................. 35

Technical Data ..................................................................................................................................................... 36


Connection Diagram ................................................................................................................................... 38

Lubricants ............................................................................................................................................................ 39

Printed Circuit Board (standard system)........................................................ 41

1
Applications ......................................................................................................................................................... 42
Mode of Operation ...................................................................................................................................... 42
Time Setting ................................................................................................................................................ 44
Operational Test / To Trigger an Additional Lubrication Cycle ................................................................... 46

Troubleshooting .................................................................................................................................................. 47

Technical Data ..................................................................................................................................................... 48


Connection Diagram ................................................................................................................................... 49
Combinations of the jumper positions - Survey ........................................................................................ 50

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

● Use the lubricant metering devices only for dispensing lubri-


cants in the centralized lubrication system fitted to your
hydraulic excavator.

General Safety Instructions

● The progressive centralized lubrication system connected to


a pump must always be secured with a safety valve.

● The lubricant metering devices fitted to this machine are state


of the art.

● Incorrect use may result in bearing damage caused by poor


or over-lubrication.

● Each outlet which will be used must be equipped with a check


valve.

● In the case of the metering devices model SSV 6 - 12 and the


block-type metering devices SSV 14 through SSV 22 the out-
lets 1 and/or 2 must never be closed. In the case of the com-
bined metering devices model SSV 14 - 22, the two outlets
with the highest numbers must never be closed.

● Unauthorized modifications or changes to an installed system


are not admissible. Any modification must be subject to prior
consultation with the manufacturer of the hydraulic excavator.

● Use only original KOMATSU spare parts (see Parts Catalog)


or the parts approved by KOMATSU.

Regulations for Prevention of Accidents

● Adhere to the regulations for prevention of accidents which


are effective in the country where the system is to be used.

Operation, Repair and Maintenance

● Repair should only be performed by:

❍ authorized and

❍ instructed personnel

❍ who are familiar with centralized lubrication system.

4
LUBRICATION SYSTEM Safety Instructions

Installation

● The metering devices have been installed to provide the opti-


mum lubrication to each available point on the excavator,
while minimising the risk of damage to the lubrication system
during operation.

● The system has been installed by the factory to allow easy


troubleshooting in case the system becomes blocked.

● Please check that the main metering devices with indicator


pin are installed so that the indicator pin is easily visible.

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.

Further information can be found in the following manuals:

Technical Description Lubrication Pump

Technical Description for ‘‘Electronic Control Units” of lubrication


pump :

Printed-Circuit Board

Installation Instructions

Parts Catalog

5
Progressive Metering Devices Model SSV LUBRICATION SYSTEM

Progressive Metering Devices Model SSV

Suitable Lubricants
Fig.1 - SSV 8 metering device, shown as a demonstration model

The progressive metering devices model SSV can be used for


dispensing:

● mineral oils of at least 40 mm²/s (cST) or

● greases up to the penetration class NLGI 2

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.

The progressive metering devices

Fig.1 SSV 8 metering devices, shown as a demonstration model.

❍ are piston-operated metering devices;

❍ automatically (progressively) dispense the lubricant fed


by the pump to the connected lubrication points;

❍ have a lubricant output of 0.2 cm³ per outlet and piston


stroke;

❍ when one or more outlets are closed (see “Combining of


outlets) they can dispense a double or multiple lubricant
quantity;

❍ are available with 6 to 12 outlets or up to 22 outlets;

❍ offer the option of combining several lubrication points


into one centralized lubrication point.

❍ reliably meter the feed lubricant in preset single quanti-


ties;

❍ can be monitored visually or electrically;

● A blockage in any lubrication circuit is indicated by grease


leaking at the corresponding pressure limiting valve

Lubricant Distribution within the Metering Device


The 5 following illustrations show how the lubricant distribution is
made to the individual outlets.

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.

● Piston A (black arrow) is moved to the left under the pressure


of the lubricant, causing the lubricant ahead of the left-hand
end of piston A to be dispensed to outlet 2 (dashed arrow).

Lubricant under pump pressure

Lubricant under piston delivery pressure

Lubricant pressureless

Phase 2

● Once piston A has reached its left-hand final position, the


junction channel to the right-hand end of piston B is opened.

● The lubricant which arrives from above (white arrow) also


moves piston B (black arrow) to the left, causing the lubricant
quantity ahead of the left-hand end of piston B to be dis-
pensed to outlet 7(dashed arrow) .

Lubricant under pump pressure

Lubricant under piston delivery pressure

Lubricant pressureless

7
Progressive Metering Devices Model SSV LUBRICATION SYSTEM

Phase 3

● Once piston B has reached its left-hand final position, the


junction channel to the right-hand end of piston C is opened.

● The lubricant which flows from above (white arrow above)


moves piston C (black arrow) to the left, causing the lubricant
quantity ahead of the left-hand end of piston C to be dis-
pensed to outlet 5.

Lubricant under pump pressure

Lubricant under piston delivery pressure

Lubricant pressureless

Phase 4

● The channel to the right-hand end of piston D is now open


(black arrow).

● The lubricant which is fed from above (white arrow above)


moves piston D to the left, causing the lubricant quantity
ahead of the left-hand end of piston D to be dispensed out of
the metering device via outlet 3 (dashed arrow).

Lubricant under pump pressure

Lubricant under piston delivery pressure

Lubricant pressureless

8
LUBRICATION SYSTEM Progressive Metering Devices Model SSV

Phase 5

● In phase 4, piston D had opened the junction channel to the


left-hand end of piston A.

● The lubricant flowing in (white arrow) moves piston A to the


right (black arrow), causing the lubricant quantity to be dis-
pensed to outlet 1(dashed arrow).

● In the subsequent distribution sequence, pistons B - D are


moved from the left to the right one after the other.

● A complete distribution sequence is finished and a new cycle


can begin.

Lubricant under pump pressure

Lubricant under piston delivery pressure

Lubricant pressureless

When the lubricant supply is interrupted

❍ the pistons come to a halt;

❍ the lubricant is no longer dispensed to the lubrication


point.

● When the lubricant is fed again to the metering device, the


cycle begins from the point where it had been interrupted.

Monitoring of the Operation

System-dependent monitoring

● The main metering device (B, Fig. 7) and the secondary


metering devices are connected by a main line G. This fea-
ture inherently links the whole progressive system down-
stream of the pump.

● If only one piston does not move in any metering device or if


the metering device can no longer dispense any lubricant via
its outlets, this metering device will block itself.

● If one of the secondary metering devices is blocked, the main


metering device is also blocked. The whole progressive sys-
tem installed downstream of the pump stops operating.

● The fundamental internal structure of the progressive meter-


ing device guarantees the self-monitoring of the sequence
within the metering device.

9
Progressive Metering Devices Model SSV LUBRICATION SYSTEM

● The linkage makes it possible to monitor the operation of the


whole system.

Fig. 7 - Example of a lubrication system

A - Safety valve E - Pressure plastic tube (dia. 6x1,5 mm)

B - Main metering device SSV 6 F - Secondary metering device SSV 12

G -High pressure plastic hose


C - Secondary metering device SSV 8
(dia. 8,6 x2,3 mm)

D - Secondary metering device SSV 6

Fig. 8 indicator pin installed on metering device

Visual monitoring

● The metering devices can be equipped with an indicator pin


which is connected to the piston and moves back and forth
during lubricant distribution.

● If there is a blockage in the system, the indicator pin stops


moving.

Fig 9. Pressure limiting valve

● The whole system can be monitored visually via the pressure


limiting valve. If lubricant is leaking at the pressure limiting
valve during the distribution sequence, this indicates that
there is a blockage in the system.

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

Electrical monitoring (microprocessor control)

Fig. 10 - Piston detector installed on metering device

● A piston detector (initiator) which has been installed on a


metering device instead of a piston closure plug (M 11 x 1)
monitors the pump operating time and brings it to a close
after all the pistons of this metering device have dispensed
their lubricant quantity.

● If there is a blockage in the system or if the pump reservoir is


empty, the piston detector can no longer record the piston
movements. The switching off signal is not transmitted to the
printed circuit board. A fault signal occurs.

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.

● The pre-assembled metering devices have the designation


SSV - N (they are available for SSV 6, 8, 10 and 12). They
must be installed in the system instead of a normal metering
device.

11
Progressive Metering Devices Model SSV LUBRICATION SYSTEM

Determining the Lubricant Output by Combining Outlets

Screw-type fittings (main metering device and sec-


ondary metering devices)

Fig. 11. Install the outlet and closure plugs in accordance with the
dosage

1. Inlet fitting 6. Valve fitting assembly

2. Delivery hole of the piston 7. Cutting ring

3. Closure plug and copper washer (M10 x1), in outlet


8. Coupling nut
borehole installed

4. Closure plug (M11 x 1), piston (chamfered) 9. Junction channel


10. Closure plug (M 10 x 1) with hex. socket head and
5. Outlet fitting assembly
sealing edge, replaces pos. 3

● The output quantities can be raised by closing outlet bore-


holes.

● Install a complete outlet fitting 5 in each outlet borehole which


will be used. Refer to Fig. 11-13.

● Never remove closure plug 4 (with chamfer) on the piston


side.

REMARK
Never use closure plug 3 (Fig. 11) as a piston closure plug (G
1/8) 4 on older models of metering devices.

● Clamping ring of valve body assembly 5 (Fig. 11) closes the


junction channels 9 to the other outlet channels.

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.

Tube Fittings, Push-in Type (main metering


device)

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)

2. Delivery borehole of the piston 6 . Junction channels

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

4. Closure plug (M 11 x 1) (chamfered), piston

13
Progressive Metering Devices Model SSV LUBRICATION SYSTEM

Tube Fittings, Plug-Type (secondary metering devices)

Fig. 13 - Install the push-in type outlets fittings and closure plugs
in accordance with the dosage

1. Inlet fitting 5. Valve body assembly (with knurled collar)

2. Delivery borehole of the piston 6. Junction channels


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

4. Closure plug (M11 x 1) (chamfered), piston

14
LUBRICATION SYSTEM Progressive Metering Devices Model SSV

Single lubricant output

● The single lubricant output is the lubricant quantity dispensed


by a piston per stroke and per outlet borehole to one lubrica-
tion point. It amounts to 0.2 cm³.

Double or multiple lubricant output

Fig 14 - Single, double and triple lubricant output

x Outlet quantity (single, double, etc.)

1... 10 Outlet numbers

A - clamping ring (brass)

● If one or several lubrication points require a double or a multi-


ple lubricant amount, this can be performed by closing one or
several outlets.

● As shown in Fig. 14, outlet borehole 10 has been closed. The


lubricant quantity supplied by this outlet flows out of the
metering device via outlet 8.

● Total quantity at outlet 8:

❍ is the quantity of outlet 8

❍ plus the lubricant quantity of outlet 10.

● 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.

Lubricant Metering Devices SSV 14 up to SSV 22


Fig. 15 - Combined lubricant metering device SSV 16

● The combined lubricant metering devices model SSV 14 to


SSV 22

❍ are combined from the basic metering devices SSV 6 to


SSV 12.

● The following differences must, however, be noted:

❍ the outlet numbers of the metering devices SSV 14 to


SSV 22 are marked in the opposite direction to those of
the SSV 6 to SSV 12 metering devices (outlets 1 and 2
are close to the inlet borehole).

❍ the two outlets -right-hand and left-hand - with the highest


number must never be closed, otherwise the system
would be blocked.

❍ if, for example, outlet 8 is closed, the lubricant quantity


dispensed to this outlet flows out of the metering device
via outlet 10, etc. Refer to ”Double or multiple lubricant
output” above.

15
Progressive Metering Devices Model SSV LUBRICATION SYSTEM

● The block-type metering devices SSV 14 through SSV 22


operate in the same way as the types SSV 6 through SSV 12

● Never close the outlets 1 and/or 2.

Tube fittings, Screw-type

Main and secondary metering device

Fig. 16: Single parts of the check valve

1. Coupling nut 3. Valve body with sealing and


2 . Cutting ring clamping ring

Inlet tube fittings

● As inlet fitting use only tube fittings R 1/8“ thread.

Check valves

● Install one complete check valve in each outlet borehole


which will be used.

● Install a closure plug in each outlet borehole which is not


required. Exception: outlet borehole 1 and/or 2 for SSV 6
through SSV 12.

Tube Fittings, Push-in Type

Metering Devices

Inlet tube fittings, straight and 90 °

NOTICE
Important ! For the inlet fittings use only tube fittings with
reinforced collar 1a (Fig. 17) and sealing ring 1b at the
thread.

Fig. 17: Inlet fittings

1a - Reinforced collar 1b - Sealing ring

Check valves

● Main metering device


Use check valves type (A, Fig. 18) with reinforced collar 1a
and smooth flange (Part no. ).

● Secondary metering device


Use check valves type B with standard collar 2a and knurled
flange (Part no. ).

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.

Fig. 18: The different types of check valve

A Check valve with reinforced collar

B Check valve with knurled collar


1a reinforced collar

2a knurled collar

Connection of the High-pressure Plastic Hose and


the Pressure Plastic Tube

Fig. 19: Check valve with reinforced collar and hose stud

High-pressure range (main metering device)

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.

Low-pressure range (secondary metering devices)

Fig. 20: Check valve wirh knurled collar and pressure plastic tube

Connect the pressure plastic tube (Ø 6 x 1.5 mm) to the check


valves with standard collet (knurled collar) and to the inlet fittings
towards the lubrication point (knurled collar).

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

Protection Cap for Push-in Type Fittings

Fig. 21: Push-in type fitting with protection cap

To prevent dirt from entering the system, the push-in type fittings,
check valves and safety valves can be equipped with protective
caps.

Plastic tubes and high-pressure plastic hoses

Plastic tube (Ø 6 x 1,5 mm)

● Use the plastic tubes only in the low pressure area,


i.e. between the secondary metering devices and the lubrica-
tion point.

● Adhere to the pressures and bending radiuses mentioned in


the chapter "Technical Data“ when installing the parts.

High-pressure plastic hoses Ø 8,6 x 2,3 mm

● Use the high-pressure plastic hose only in the high pressure


area, i. e. between the pump, main metering device and sec-
ondary metering devices.

● Adhere to the pressures and bending radiuses mentioned in


the chapter "Technical Data“ when installing the parts.

Fig. 22 - Preassembly of the threaded sleeves and hose studs on


the high-pressure plastic hose

1. Threaded sleeve 3. Hose stud

2. High- pressure plastic hose

Fitting the threaded sleeves and hose studs on the high-


pressure plastic hose

● Screw the threaded sleeve, item 1 Fig. 22, counterclockwise


onto the high-pressure plastic hose 2 until the illustrated
dimension of 11 mm is reached. Then screw the hose stud 3
into the threaded sleeve 1.

NOTICE
Important: Before screwing the parts 1 and 3, rub them with
oil.

NOTE: The outside diameter of the high-pressure plastic hose


may show variations in dimension. In such a case, press
the threaded sleeve 1 at the end where it will be screwed

18
LUBRICATION SYSTEM Progressive Metering Devices Model SSV

onto the high-pressure plastic hose so that it becomes


oval in shape (1 to 2 mm). This will prevent the high-pres-
sure plastic hose from being pushed out of the sleeve
when the hose stud is screwed.

Fig. 23 - Preassembly of the threaded sleeves by means of an


adjusting gauge

1. Threaded sleeve 3. Adjusting gauge


2. High-pressure plastic hose

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

Fault : Blockage in the downstream progessive system

Cause Correction

● Find out which is the cause of the blockage and


● Bearing, lines or metering device clogged.
rectify it in accordance with he following example:

● In the case of the metering devices SSV 6 through


12 and with the combined metering devices SSV
14 through SSV 22 the outlet boreholes 1 and/or 2 ● Allow pump to run (see ”To trigger an additional
are closed. In the case of the combined metering lubrication cycle”).
devices SSV 14 through 22 the two outlet bore-
holes with the highest numbers are closed.

● Loosen all high-pressure plastic hoses G leading to


The fault can be identified by:
the secondary metering devices one after the other
a) grease leaking at the safety valve;
from the main metering device (B, Fig. 24) . If, for
b) the fact that the indicator pins (if any) installed on
example, grease or oil emerges under pressure
the metering devices no longer move;
from outlet 1 of main metering device B, the block-
c) the fault signal of the signal lamp (if any) or LED
age will be found in the lubrication circuit of the sec-
function indication
ondary metering device D.

Note :If there is a blockage in the downstream sys-


tem, the high-pressure plastic hoses are under pres-
sure. In such a case, it is difficult to detach the push-in
type connection parts of the high-pressure plastic
hose. Relieve the system by removing the closure
plug on the push-in type safety valve (at the pump) or,
if any, by removing the filling nipple.
● Let the pump run.
● Disconnect all pressure plastic tubes E from sec-
ondary metering device D one after the other. If, for
example, grease or oil emerges under pressure
from outlet 3 of metering device D, the blockage
will be found in the line of outlet 3 or in the con-
nected bearing.
● Pump the blocked bearing or line through by
Fig. 24 - Example of a lubrication system means of a manual pump.
A - Safety valve Note :When checking the individual outlets, keep
B - Main metering device each outlet loosened for quite a while because per
C - Secondary metering device SSV 8 each motor revolution there is only one piston stroke.
D - Secondary metering device SSV 6 A complete cycle of all metering devices requires sev-
E - Pressure plastic tube eral strokes.
F - Secondary metering device SSV 12 ● Check safety valve A. Replace it, if necessary.
G - High-pressure plastic hose

20
LUBRICATION SYSTEM Troubleshooting

Fault: Blockage in the downstream progressive system (continued)

Cause Correction

● Replace the metering device or clean it in accor-


dance with the following procedure:
● Remove all tube fittings.
● Unscrew the piston closure plugs.
● If possible, try to eject the piston using a smooth
drift (Æ smaller than 6 mm; 0.24 in.).
● Important: The pistons are precision-fitted into the
holes. Mark the pistons with regard to their installa-
tion position and direction after they have been
removed. They must not be exchanged.
● Thoroughly clean the metering device bodies in a
fat-dissolving washing agent, blow them through
with compressed air.
● Metering device blocked
● Press free the slant ducts (Ø 1.5 mm; 0.59 in.) at
the thread ends of the piston holes using a pin.
● Clean the metering devices again and blow them
through.
● Reassemble the metering devices.
● If copper washers are used, replace them.
● Before the tube fittings are reassembled, the
metering devices should be pumped with oil
through several cycles by means of a manual
pump. Check that the pressure in the metering
device does not exceed 25 bar (362.8 psi).
● If the pressure is higher, replace the metering
device

Fault: Differing lubricant amounts at the lubrication points

Cause Correction

● Check the lubricant metering acc. to the lubrication


● Lubricant metering not correct
chart

● Respective valve body has been assembled with-


● Remove the valve body and install a clamping ring
out clamping ring

● Setting of the pause time or operating time incor- ● Check the time setting. Refer to the corresponding
rect setting in the respective “Operating Instructions”.

Fault: Over- or underlubrication of the lubrication points

Cause Correction

● Check the time setting at the control units or


● Setting of the operating time or pause time incor-
printed-circuit boards. Refer to the corresponding
rect
setting in the respective “Operating Instructions”.

21
Technical Data LUBRICATION SYSTEM

Technical Data

Metering Device Model SSV

Lubricant output per outlet and per stroke 0.2 cm³


Max. operating pressure 350 bar

Min. operating pressure 20 bar

Max.differential pressure between two outlets 100 bar


Outlet connection for tube ø 6 mm

Inlet connection G 1/8

Operating temperature - 25° C to 70°C

Push-in Type Tube Fittings

High pressure range,


Inlet tube fittings of the metering devices p max. 350 bar
Outlet fittings, main metering device

Low-pressure range,
Outlet fittings, secondary metering devices p max. 250 bar
Inlet fittings to the lubrication point

Lines

High-pressure plastic hose (dia. 8,6 x2,3 mm)

Min. bursting pressure (in connection withscrew-type connectors). 600 bar

Min. bending radius. 35 mm

Min. temperature - 40° C

Pressure plastic tube (dia. 6x1,5 mm)

Min. bending radius 50 mm

Bursting pressure at 20° C approx.210 bar

Min. temperature - 40° C

22
LUBRICATION SYSTEM Tightening Torques

Tightening Torques

Closure plug (piston) in metering device 10 Nm


Closure plug (outlets) in metering device 10 Nm

Inlet fitting in metering device

screw-type 17 Nm
push-in type 10 Nm

Outlet fitting in metering device

screw-type 10 Nm

push-in type 8 Nm

Compression nut onto inlet fitting 10 Nm

Compression nut onto outlet fitting, screw-type


plastic tube 5 Nm

steel tube 10 Nm

Indicator pin in metering device 12 Nm

Piston detector on metering device 12 Nm

Proximity switch on metering device 12 Nm

Mounting of the metering device 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.

Recommended greases for centralised lubrication


systems

Grease
Manufacturer (Lithium base)
NLGI No. 2

G2-LI
KOMATSU
G2-LI-S

AGIP GR MU/EP

AMOCO RYKON premium grease

Litholine HEP 2
ARCO
Arco EP moly D

BP Energrease LS-EP2

Marfak all prupose 2


CALTEX
Ultra duty grease 2
MS3
CASTROL
Spheerol EPL2

CHEVRON Ultra duty grease 2

CONOCO Super -sta grease


Tranself EP
ELF
Tranself EP Type 2

EXXON (Esso) Beacon EP2

Gulfcrown EP2
GULF
EGulfcrown EP special

Mobilux EP2
MOBIL Mobilgrease 77
Mobilgrease special

Multi purpose white grease


705
PENNZOIL
707L White Bearing
grease

PETROFINA FINA marson EPL2


SHELL Albania EP grease

24
LUBRICATION SYSTEM Lubricants

Grease
Manufacturer (Lithium base)
NLGI No. 2

Sunoco ultra prestige 2EP


SUN
Sun prestige 742

Multifak EP2
TEXACO
Starplex 2

TOTAL Multis EP2

UNION Unoba EP

25
Lubricants LUBRICATION SYSTEM

26
Central Lubrication Pump

27
Safety Instructions Central Lubrication Pump

Safety Instructions

Appropriate Use

● Use pump only for the delivery of lubricants in the centralised


lubrication systems fitted to your Komatsu Excavator. The
pump is designed for intermittent operation.

General Safety Instructions

● The centralised lubrication system fitted to this machine

❍ is state of the art;

❍ is assembled for safe operation

● Incorrect use may result in bearing damage caused by poor


or over-lubrication.

● Unauthorised modifications or changes to this system are not


allowed. Any modifications must be subject to prior consulta-
tion with KOMATSU.

Regulations for prevention of accidents

● Observe the regulation for prevention of accidents which are


effective in the country where the pump is to be used.

Operation, Maintenance and Repair

● Repair should only be performed by authorised and instructed


personnel who are familiar with the instructions.

● The central lubrication pump must only be operated with


safety valve installed.

● The central lubrication pump must be regularly refilled with


clean lubricant.

CAUTION
In the case of pumps which are filled from top, the voltage
supply must be switched off before the lubricant is filled in.

● The centralised lubrication system operates automatically.


However, a regular check (approx. every 50 - 100 operating
hours - depending upon operating environment and opera-
tor’s discretion.) should be made to ensure that lubricant is
emerging from all lubrication points.

● Defective printed circuit boards should be properly packed


and returned to the factory.

● Used or dirty lubricants must be disposed of in accordance


with the environmental legislation.

28
Central Lubrication Pump Safety Instructions

● The manufacturer will not accept any liability

❍ for damages due to the use of greases which are not or


only conditionally pumpable in centralized lubrication sys-
tems

❍ for damage caused by insufficient lubricant and irregular


pump filling

❍ for damage caused by the use of contaminated lubricants

❍ for damage caused by inadequate disposal of used or


contaminated lubricants

Installation

● Safety equipment

❍ should not be modified or made ineffective

❍ should only be removed for the purpose of installation of


the pump

❍ must be replaced after the pump has been installed.

● The central lubrication pump must be kept away from


sources of heat.

● Use only original KOMATSU spare parts (see Parts Catalog)


or parts approved by KOMATSU.

● The manufacturer will not accept any liability for:

❍ damage caused by unauthorised modification of system


components,

❍ damage caused by the use of unapproved parts.

29
Central Lubrication Pump Central Lubrication Pump

Central Lubrication Pump


● The central lubrication pump is a compact multiline pump
consisting of the following subassemblies:

housing with integrated motor

reservoir with stirring paddle

printed circuit board (p.c.b.)

pump element

safety valve

filling nipple

electrical connection parts

❍ can drive up to three pump elements

❍ operates according to cycles (pause and operating


times)

❍ can be equipped with a low-level control

❍ can service up to 300 lubrication points depending on the


length of lines

❍ is designed for the automatic lubrication of the connected


lube points

❍ is designed for the delivery of greases up to NLGI grade 2


at temperatures from -25° to 70° C or mineral oils of at
least 40 mm²/s (cSt).

● can be used at low temperatures of down to -40° C.

● During the operating time the pump dispenses lubricant to the


connected lube points via several metering devices.

Fig. 1 - Parts of the pump

1. reservoir 5. connection plug 2A1

2. pump element 6. filling fitting, pump


3. safety valve 7. p.c.b.

4. filling fitting, system emer- 8. connection plug 1A1


gency lubrication possible 9. return line connection

Low-level control (Option)

● The central lubrication pump can be equipped with a low-level


control for grease or oil operation.

● As soon as the reservoir is empty, this will be indicated by a


flashing signal lamp

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).

● During the operating time the piston (1) sucks in lubricant


from the reservoir and delivers it to the connected lube points
via metering devices.

1. piston 2. pull-back spring 3. check valve

Pressure relief valve

NOTICE
Important! Each pump element must be protected by means Fig. 6 - Pressure relief valve
of a pressure relief valve.

● The pressure relief valve

❍ limits the pressurisation in the system

❍ opens at 350 bar

❍ If lubricant is emerging at the pressure relief valve, this


indicates a fault in the system.

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.

● If a control unit is fitted to the pump, it is an integrated printed


circuit board.

Commissioning

The pump is ready to operate as soon as the machine con-


tact is switched on

31
Maintenance, Repair and Tests Central Lubrication Pump

Maintenance, Repair and Tests

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.

● Make sure that the lubricant reservoir is refilled in good time.

● Check regularly that lubricant is actually reaching all lubrica-


tion points.

● Also regularly check the high-pressure plastic hoses and


plastic tubes for damage. Carry out this check as part of the
daily safety check of the machine, carried out before starting
operations. If necessary, replace the plastic tubes.

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.

● For cleaning the system use naphtha or petroleum benzine.


Tri, per or similar solvents must not be used. Do not use polar
organic solvents such as alcohol, methyl alcohol, acetone or
similar.

To Fill Pump

2 l - Reservoir Fig. 8 - Filling of pump reservoir

Fill the reservoir via the filling fitting up to the “max.” mark.

Use grease up to NLGI grade 2 or mineral oils of at least


40 mm²/s (cSt).

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

● Only original KOMATSU spare parts must be used for repairs


on the pumps, see Spare Parts List.

32
Central Lubrication Pump Maintenance, Repair and Tests

● The pump should be returned to the factory for warranty work


or major repairs.

Printed circuit boards

● See under “Repair” in the respective Technical Description of


the p.c.b.

Replace the pump element Fig.9- Replacing the pump element

1. Remove the pressure relief valve from the pump element

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.

3. Install a new pump element and a new sealing ring.

Tests

Test run / Triggering an additional lubrication

A test can be performed for checking the operation of the pump.


See Operating Instruction of the respective control unit.

To check the system

● To check the system, trigger one or several additional lubrica-


tion cycles.

REMARK
Each time an additional lubrication cycle is initiated, the pump
supplies grease or oil to the connected lubrication points.

● Check high-pressure plastic hoses and plastic tubes for leak-


ages.

● Check whether lubricant is emerging at all lubrication points.

● Check the settings of the operating and/or pause time on the


control unit. Refer to the Operating Instruction of the respec-
tive control unit.

● If necessary, re-adjust the pause time or the monitoring time


in accordance with the respective application.

33
Maintenance, Repair and Tests Central Lubrication Pump

To Check the Safety Valve

Fig 10. To check the safety valve

1. hose line, min. length: 1m 3. pressure gauge

2 . Tee 4. relief cock

Either

● Connect the pressure gauge (0 - 600 bar, 0 - 8708 psi) to the


safety valve (Fig. 7).

● Trigger an additional lubrication

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.

● The safety valve should open at a pressure of 350 bar (5080


psi).

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.

Fault of pump: motor does not run

Cause Remedy

● Check voltage supply or fuses. If necessary, rectify the


● Voltage supply interrupted fault and replace fuses.

● Check the line leading from the fuses to the pump plug.

● Check voltage supply to motor. If necessary, replace


● Electric motor defective
motor.

Faults: Pump does not deliver the lubricant

Cause Remedy

Note: If a lubricant low-level control is available, the low level


is indicated by the flashing light of the signal lamp in the
case of pumps without printed circuit board. The flashing fre-
quency depends on the speed of the motor.
● Refill reservoir with clean grease or oil. Allow pump to run
● Reservoir empty
(additional lubrication) until lubricant issues from all lubri-
cation points.
Note: Depending on the ambient temperature and/or type of
lubricant it may take 10 minutes of operation until the pump
elements will reach their full lubricant output.

● Trigger an additional lubrication. Loosen the outlet fitting


● Air pockets in lubricant or main line on safety valve. Lubricant must issue without
air bubbles.

Note: When push-in type fitting are used, the high-pressure


plastic hose which is under pressure cannot be easily dis-
connected from the safety valve. For this purpose, loosen
● Unsuitable lubricant has been used the closure plug or, if any, the filling nipple on the safety
valve in order to relieve the high-pressure plastic hose.

● Renew the lubricant. See Lubricant List.

● Remove pump element. Check suction hole for foreign


● Suction hole of pump element clogged
particles. If there are any, remove them.

● Pump piston worn ● Replace pump element

● Check valve in pump element defective or


● Replace pump element.
clogged

35
Technical Data Central Lubrication Pump

Technical Data

Pump

Admissible operating temperature -25° C to70° C*


Number of outlets 1,2 or 3

Reservoir capacity 2 l, 4 l, 8 l

via hydraulic lubrication fitting or from


Refilling
top
greases up to NLGI grade 2 mineral oils
Lubricant
of at least 40 mm²(s (cSt) at 40° C

Protection IP6K 9K acc. to DIN 40050 T9

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:

DC gear motors (interference-.suppressed)

Operating voltage 12VDC or 24VDC

Max. power input

12V 6.5 A

24V 3A

Speed approx. 17 rpm

NOTE: The pump motor is designed for intermittent operation.

Pump element with fixed lubricant output

Piston diameter, K5 5 mm
Lubricant output approx. 2 cm³/min

Piston diameter , (Standard) K6 6 mm

Lubricant output approx. 2.8 cm³/min


Piston diameter , K7, C7 7 mm

Lubricant output approx.4 cm³/min

Max. operating pressure. 350 bar


Connection thread. G 1/4

Suitable for tube dia 6 mm

36
Central Lubrication Pump Technical Data

Pump element with adjustable lubricant output

Piston diameter, KR 7 mm

Lubricant output 0.7 - 3 cm³/min / 0.04 - 0.18 cm³/stroke

Max. operating pressure. 350 bar

Connection thread. G 1/4

Suitable for tube dia 6 mm


Suitable for tube dia 8 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

Fig. 11 - Connection diagram without control unit


Connection via Hirschmann connector DIN 43650-A-A

A. pump housing F. low-level control

B. connection plug 1 switching capacity max. 60 W/VA

C. line socket 1 with connection cable, 3-wire switching voltage max. 230 VAC

D. connection plug 2 switching current max. 1 A

E. line socket 2 M. electric motor

NOTE: All further connection diagrams can be seen in the


respective Technical Description.

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.

Lubricating greases for Automatic Grease Sys-


tems

Grease
Manufacturer (Lithium base)
NLGI No. 2

G2-LI
KOMATSU
G2-LI-S

AGIP GR MU/EP

AMOCO RYKON premium grease

Litholine HEP 2
ARCO
Arco EP moly D

BP Energrease LS-EP2

Marfak all prupose 2


CALTEX
Ultra duty grease 2

MS3
CASTROL
Spheerol EPL2

CHEVRON Ultra duty grease 2

CONOCO Super -sta grease


Tranself EP
ELF
Tranself EP Type 2

EXXON (Esso) Beacon EP2

Gulfcrown EP2
GULF
EGulfcrown EP special
Mobilux EP2
MOBIL Mobilgrease 77
Mobilgrease special

Multi purpose white grease


705
PENNZOIL
707L White Bearing
grease

PETROFINA FINA marson EPL2

SHELL Albania EP grease

39
Lubricants Central Lubrication Pump

Grease
Manufacturer (Lithium base)
NLGI No. 2

Sunoco ultra prestige 2EP


SUN
Sun prestige 742

Multifak EP2
TEXACO
Starplex 2
TOTAL Multis EP2

UNION Unoba EP

NOTE: Never use lubricants with solid matter additives.

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

Fig. 2 - Driving switch

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).

● The sequence of the pause and operating times is activated


when the machine contact or driving switch is switched on.

● 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

● During the operating time the pump element dispenses the


lubricant to the lubrication points via progressive metering
devices.

Fig. 5 - Time sequence diagram

tB -Working hours T -Lubrication cycle


tP. Various pause times T1. Stored pause times

T2. Operating times

The pause time

❍ determines the frequency of the lubrication cycles within


a working cycle;

❍ is started and stopped via the machine contact or driving


switch;

❍ is adjustable.

● When the machine contact or the driving switch is switched


off, the pause times which have already elapsed are stored
and added up (refer to T1, Fig. 5) until the time which has
been set on the blue rotary switch (Fig. 7) is reached.

● The pause time setting may be different for each application.


It must be adjusted in accordance with the respective lubrica-
tion cycles. Also see ”To set the pause time”.

The operating time

❍ depends on the system’s lubricant requirement ;

❍ is adjustable;

❍ is finished when the machine contact or the driving switch


is switched off.

● The longer the operating time, the greater the lubricant


requirement and vice-versa.

● When the machine contact or the driving switch is switched


off, the operating times which have already elapsed are
stored and added up until the time which has been set on the
red rotary switch (Fig. 11) is reached. After this, the lubrica-
tion cycle starts again.

● The operating time setting may be different for each applica-


tion. It must be adjusted in accordance with the respective
lubricant requirement. Also see ”To set the operating time”.

Time storage

● When switching of the ignition voltage and/or the operating


voltage the times already expired are saved for an unlimited
duration.

43
Applications Printed Circuit Board (standard system)

● When the power supply is switched on again the printed cir-


cuit board continues to operate from the point where it had
been interrupted.

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

To set the pause time

The pause time can be set to 15 different settings by means of Fig. 7 - Rotary Switch Pause Time
the blue rotary switch.

Time ranges: Minutes or hours

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

Fig. 8 - Preselection of the time range

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

Rotary switch on : 6 hours

or 24 minutes

44
Printed Circuit Board (standard system) Applications

● The time ranges can be modified by replugging the jumper


(Fig. 8) on the printed circuit board.

● Factory setting of the jumper: see “Combinations of the


jumper positions - Survey” on page 50. The combination
number can be learnt from the pump type designation code
mentioned on the nameplate of each pump.

To set the operating time

● The operating time can be set to 15 different setting by Fig. 9 - Rotary switch - Operating time
means of the red rotary switch.

Time ranges: Seconds or minutes

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

. Fig. 10 - Preselection of the time range

Factory setting

Rotary switch on : 6 minutes

or 24 seconds

● The time ranges can be modified by replugging the jumper


(Fig. 10) on the printed circuit board.

● Factory setting of the jumper: see “Combinations of the


jumper positions - Survey” on page 50. The combination
numbers can be learnt from the pump type designation code
mentioned on the nameplate of each pump.

Fault indication

Rotary switch set at "0“

● When one of the rotary switches 2, 3 Fig. 11 is on the "0“ set-


ting a fault is shown at the right-hand LED 3.

● The fault is indicated by 4 flashes of the LED.

45
Applications Printed Circuit Board (standard system)

● The pump motor also runs according the flash frequency. If


the warning is ignored the controller automatically adopts the
factory-set values for the operating or pause time

Push button 5 Fig. 11 continuously actuated (short circuit)

● If a short circuit occurs at the pushbutton or is present at the


external illuminated pushbutton Fig.12 or at the connecting
parts a fault is shown at the red LED 3, fig. 11.

● The fault is indicated by 3 flashes of the LED when the volt-


age supply is switched on.

● The motor of the pump also runs according to the flash fre-
quency.

Repair

The defective printed circuit boards should be suitably packed


and returned to the factory.

NOTE: Before installing another printed circuit board, take care


that the setting of the jumper or that of the operating/
pause time is the same as on the old printed circuit
board.

Operational Test / To Trigger an Additional Lubrication Cycle


● To check the pump operation it is possible to perform an Fig. 11 - LED on the printed circuit board
operational test.

4 - Rotary switch, operating


1 -LED, left-hand
time

2 -Rotary switch, pause time 5 - Pushbutton for additional


3 -LED, right-hand lubrication

Switch on the driving switch

1. To check whether power is applied to the printed circuit


board, observe whether the LED 1 Fig. 11 is lit.

2. Press pushbutton 5 on the printed circuit board (> 2 seconds)


until the right-hand LED 3 lights up.

3. A shorter pause time elapses, followed by a normal lubrica-


tion cycle.

4. Additional lubrication cycles can be triggered at any time.

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.

Fault: the pump motor does not run

Cause Remedy

● Check the voltage supply to the pump. If neces-


● Voltage supply interrupted
sary, eliminate the fault.

● Check the line leading from the pump plug to the


● Voltage supply to the printed-circuit interrupted printed circuit board.
● If the voltage is applied, the left-hand LED is lit.

● 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.

● Printed-circuit board defective ● Replace the printed circuit board.

Fault: Right-hand LED 3 Fig. 12 flashes

Cause Remedy

● One of the two rotary switches 2, 4 Fig. 12 is on "0“.


● Set rotary switch to a number or a letter.
Signal: 4 flashes

● 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

Rated voltage 24V DC

Operating voltage 24V 9V to 30V

Residual rippple in relation with the operating voltage ± 5% acc. to DIN 41755

Motor output Transistor 7A/short-circuit proof


Reverse voltage protection:

● The operating voltage inputs are protected against polarity


reversal

● Temperature range -25°C to 70°C


Lamp current max. 2 A

Class of protection

Printed circuit board installed in housing IP 6K 9K

In order to protect the printed circuit board against condensation it


has been covered with a protective varnish.

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

EN 55011 / 03.91 and


Emitted interference acc. to
EN 50081-1 / 01.92

Noise immunity acc. to EN 50082-2 / 03.95

The pumps comply with the Automotive EMC Directive 95/54/


EEC and with the EC approval mark e1 (021016) shown on the
nameplate

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

Operating time minutes

or seconds

48
Printed Circuit Board (standard system) Technical Data

Connection Diagram

DO NOT CONNECT

Fig. 16 - Connection diagram (with adjustable pause time)

Connection via square type plug DIN 43650-A

2A1 -Pump with cable connection


A -Printed circuit board K - Cable connector 2**
for illuminated pushbutton**
L - Line socket 2 (grey) with con-
B -Pump housing F - Driving switch
nection cable, 3-wire*

C -Cable connector 1 G - Fuse 10 A M - Illuminated pushbutton**

D -Line socket 1 (black) with con- O - Signal lamp in the case of low-
H - Cable, black
nection cable, 3-wire level control

1A1 - Pump without illuminated


I - Cable, brown P - Battery cutoff*
pushbutton

*does not belong to the scope of delivery

**equipment available on request

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)

Combinations of the jumper positions - Survey

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