Komatsu 830E, Shop Manual

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P03022 Automatic Lubrication System P3-11
PUMP REBUILD
Be certain to bleed steering accumulators to
relieve hydraulic pressure and to relieve pump
outlet grease pressure before removing any
hoses or fittings.
Disassembly
1. Remove the four socket head screws (33, Fig-
ure 3-9) and separate the manifold (37) from
the hydraulic motor (42).
2. Remove pipe plug (45) and drain the crankcase
oil from pump housing (46).
3. Remove the six screws (29) and remove the
housing cover (30) and cover gasket (31).
4. Remove retaining ring (57) and pull the shovel
plug (56) from the housing tube (55).
5. Remove two socket head screws (44) and sepa-
rate hydraulic motor (42) from the pump hous-
ing (46).
6. Remove two outlet pin nuts (50) from pump
housing.
7. Remove the pump subassembly (1 through 28)
from the pump housing. Pushing the subassem-
bly up with a 0.75 in. (19 mm) diameter wooden
or plastic rod against the check seat housing
(28) is helpful.
8. Remove the housing tube (55) from the pump
housing by inserting a 0.75 in. (19 mm) diame-
ter rod through the inlet holes at the bottom of
the housing tube and unscrewing it.
9. Remove the bronze bearing (51), O-ring (52),
backup washer (53), and O-ring (54) from the
housing tube.
10. Remove the crankrod assembly (1 through 8)
from the pump by unscrewing the button head
screws (12) and then pulling out the wrist pin
bushings (13).
11. Remove the check seat housing (28) from the
reciprocating tube (21).
Note: There is a 3/8 in. allen head socket in the
throat of the check seat housing to facilitate removal.
12. Unscrew the wrist pin anchor (14) from the recip-
rocating tube (21) and pull the plunger assem-
bly (9 through 20) from the tube.
13. Using a 0.50 in. (13 mm) diameter wooden or
plastic rod, push the cup seal (22) and the
pump cylinder (24) from the reciprocating tube.
14. Remove the pump plunger (20) from the plunger
link rod (17). (A spanner wrench, which uses
the holes in the pump plunger, is required.)
15. Unscrew the plunger link rod (17) from the
plunger tube (11) and slide off the cup seal (16)
backup washer (15) and wrist pin anchor (14).
16. Unscrew the plunger tube (11) from the outlet pin
(9).
17. To dismantle the crankrod assembly (1 through
8), remove flat head screws (1) and the inner
and outer weights (2 & 3).
18. Remove the small retaining rings (6) and press
the crank eccentric (7) out of the ball bearing
(8). Be sure to support the ball bearing on the
inner race.
Cleaning and Inspection
1. Discard all seals and gaskets. Repair kits are
available containing all the necessary seals and
gaskets for reassembly. Refer to the appropri-
ate truck parts book.
2. Clean and inspect the following parts. Replace if
excessive wear is evident:
• Ball bearing (8)
• Crank eccentric (7)
• Crankrod (5)
• Wrist pin bushings (13)
• Plunger tube (11)
• Pump plunger & upper check parts (20, 19 & 18)
• Pump cylinder (24)
• Check seat housing/lower check ball (28, 26)
• Upper bronze bushing (51)
• Housing tube (55)
• Shovel plug (56)
• Reciprocating tube (21)