Komatsu 830E Shop Manual page 412

4. Disconnect and remove the hose at the alterna-
tor end and swing clear of work area.
5. Close the shut-off valves (2 & 10, Figure 3-1).
Always maintain complete cleanliness when
opening any hydraulic connection. Insure that all
system lines and components are capped while
the component is removed from the truck.
6. Cap or cover all lines and pump inlets and out-
lets to prevent contamination.
7. Remove the capscrews securing the hoist pump
drive flange to the drive shaft.
8. Loosen the capscrews securing the inlet hoses
(3) and outlet hoses (6) on the hoist pump and
allow oil to drain. Remove inlet and outlet
hoses.
The hoist pump weighs approximately 282 lbs
(128 kg). The hoist and steering pump together
weigh approximately 500 lbs (227 kg). Use a suit-
able lifting or support device that can handle the
load safely.
9. Attach a suitable lifting or support device to the
hoist pump capable of handling approximately
250 lbs (113 kg). Attach a support to the front
end of the steering pump to hold it in place dur-
ing removal of the hoist pump.
10. Remove the four capscrews securing the hoist
pump to the front support bracket. Remove the
six capscrews holding the support bracket to
the "T" bracket and remove support bracket.
11. Make sure the lifting and support devices are in
place on both pumps. Loosen (but do not
remove) the rear support bracket capscrews
holding the steering pump. Lower the pumps
allowing hoist pump to come down further than
steering pump.
12. Remove the four capscrews (10, Figure 3-2).
Slide hoist pump forward to disengage the
splines of drive coupling (9) from the steering
pump.
13. Move pump to a clean work area for disassem-
bly.
L3-2
Installation
NOTE: The following procedure assumes the
steering pump is already in position on the truck.
1. Install O-ring (16, Figure 3-2) to steering pump
(11). Install coupler (9) to hoist pump. If
removed coupler has a snap ring, remove the
snap ring and dispose.
The hoist pump weighs approximately 282 lbs
(128 kg). The hoist and steering pump together
weigh approximately 500 lbs (227 kg). Use a suit-
able lifting or support device that can handle the
load safely.
2. Attach a suitable lifting or support device to the
hoist pump capable of handling approximately
250 lbs (113 kg). Move pump into position in
truck.
3. Lubricate the steering pump spline shaft and
align with coupling (9). Install hoist pump to
steering pump and install capscrews (10) with
hardened washers and tighten to standard
torque. Raise pumps up into position.
4. Attach front support bracket to the "T" bracket
and to the pump with capscrews, lockwashers
and nuts. Tighten capscrews to standard
torque.
5. Connect hoist pump drive flange to drive shaft
with capscrews, lockwashers and nuts. Tighten
to standard torque.
6. Tighten support bracket capscrew (on rear of
steering pump) to standard torque.
7. Uncap inlet and outlet hoses and install to
pumps using new O-rings. Tighten capscrews
securely.
8. Service the hydraulic tank with C-4 type hydrau-
lic fluid. Refer to Hydraulic Tank, this section for
filling instructions.
9. Open the three suction line shut-off valves.
Loosen capscrews (at the pump) on suction
hoses (12 & 16) to bleed trapped air. Then
loosen capscrews (at the pump) on pressure
hoses to bleed any trapped air. Tighten all cap-
screws securely.
NOTE: If trapped air is not bled from steering pump,
possible pump damage and no output may result.
10. Reconnect blower tube and install blower tube
support strap.
Hydraulic Component Repair 7/02 L03026