Installation; Radiator Filling Procedure - Komatsu 830E Shop Manual

Service
Radiator service is a specialized function usually not
accomplished by most maintenance shops. The
large size and weight of the off-road truck radiators
requires that a radiator repair shop equipped with
special tools and handling equipment be used for
service and repair.

Installation

1. Reinstall shroud (1, Figure 3-4), air conditioner
condenser, and fuel cooler. Install air condi-
tioner receiver/drier (10) if removed.
The radiator assembly weighs approximately
4,200 lbs. (1907 kg.) Be sure lifting device is
capable of lifting the load.
2. Attach lifting eyes in tapped blocks at upper cor-
ners of radiator assembly (6, Figure 3-4). Attach
hoist and lift into place on power module sub-
frame.
3. Position radiator assembly to equalize gap
between tip of fan blades and shroud at right
and left sides. Install mounting hardware (2,
Figure 3-3) through lower mounts and tighten to
220 ft.lbs. (298 N.m) torque.
4. Install radiator support rods (3, Figure 3-4). If
necessary, adjust to position radiator perpendic-
ular to the subframe. Tighten the support strut
locknuts. Install upper support rods to brackets
on front upright supports.
5. Adjust fan shroud ring vertically to equalize gap
between tip of fan blades and ring.
6. Lift grille structure (2, Figure 3-2) into position
and install mounting hardware.
7. Route headlight wire harness to lights. Attach
connectors to lights and clamp harness at weld
studs.
8. Install upper and lower radiator piping. Seat
hoses and clamps securely.
9. Position fan guard against shroud and tighten
mounting hardware to 40 ft.lbs. (55 N.m)
torque. (If halves of guard were disassembled,
tighten capscrews clamping halves together to
25 ft.lbs. (34 N.m) torque.
10. Attach hoses to fuel cooler.
11. Route A/C condenser hoses to condenser and
attach. Install lower grille sections. Install
C3-4
receiver/drier (10) hoses. Connect pressure
switch (11).
12. Install surge tank hoses and electrical wiring to
the coolant level probe (9, Figure 3-4). Clamp
hoses and electrical cables to the shroud. Install
surge tank cover.
13. Make sure all coolant drains are closed, hoses
are installed, and all wiring reconnected. Close
drain valve on main air tank.
14. If the truck is equipped with air conditioning, the
system must be evacuated and recharged.
Refer to "Heater/Air Conditioning System" in
Section M for detailed instructions for recharg-
ing with refrigerant.
15. Service the cooling system per the instructions
below.
16. Check for static leakage and correct any leaks.
After servicing is complete, start the engine and
run until normal operating temperature is
reached. Repeat check for leaks and correct as
required.

RADIATOR FILLING PROCEDURE

Cooling System is pressurized due to thermal
expansion of coolant. DO NOT remove radiator
cap while engine and coolant are hot. Severe
burns may result.
1. With engine and coolant at ambient tempera-
ture, remove radiator cap.
Note: If coolant is added using the Wiggins quick fill
system, the radiator cap MUST be removed prior to
adding coolant.
2. Fill radiator with proper coolant mixture (as
specified by the engine manufacturer) until
coolant is visible in the sight gauge.
3. Install radiator cap.
4. Run engine for 5 minutes, check coolant level.
5. If coolant is not visible in the sight gauge, repeat
steps 1 through 4. Any excess coolant will be
discharged through the vent hose after the
engine reaches normal operating temperature.
Engine coolant must always be visible in the
sight gauge before truck operation.
Cooling System C03027