Komatsu 830E-AC Shop Manual page 579

9. If the manifold has to be removed from the
truck, remove accumulators and disconnect
hydraulic lines and wires necessary to allow
removal of the manifold.
10. Plug lines and ports to prevent possible contam-
ination.
11. Remove mounting hardware and move brake
manifold to a clean work area for disassembly.
Installation
1. Install brake manifold in truck and tighten
mounting hardware to standard torque.
2. Connect all lines and electrical connections to
proper locations.
3. Install brake accumulators.
4. Charge brake accumulators with nitrogen.
Refer to Charging Procedure in the brake accu-
mulator service area for complete charging
instructions.
5. Start truck and check for leaks and proper oper-
ation.
6. Shut down engine and check for proper oil level
in hydraulic tank.
Disassembly
1. Mark all plugs, valves and cartridges before
removal to insure proper assembly.
2. Remove plugs, valves and cartridges.
NOTE: Check Valve (7, Figure 3-24) and Reducing
Valve (6) both have an orifice disc located below
them. Do not mix these up, as the orifices are
different sizes.
Cleaning and Inspection.
1. After disassembly, clean all parts with an
approved cleaning solution.
2. Blow all parts dry with air and keep free from
foreign matter.
3. Replace all O-rings and any other items
deemed unsuitable for further usage.
J03034
Assembly
1. Install new O-rings on all components that were
removed from the manifold.
2. Coat all bores, cartridges and O-rings with
clean C-4 hydraulic oil.
3. Before installing Check Valve (7) or Reducing
Valve (6), refer to Figure 3-25 for proper orifice
disc installation. The orifice discs must be
installed in the direction shown for proper oper-
ation.
4. Install all cartridges in the bores from which
they were removed from and tighten securely.
1. Cartridge
2. Brake Manifold
Brake Circuit Component Service
a. Check Valve (7) orifice size - 1.58 mm (0.062
in.).
b. Reducing Valve (6) orifice size- 2.54 mm
(0.100 in.).
FIGURE 3-25. ORIFICE INSTALLATION
3. Cavity
4. Orifice Disc
J3-25