Power Module; Preparation; Removal - Komatsu 830E Shop Manual

The radiator, engine and alternator/blower assemblies
are mounted on a roller equipped subframe which is
contained within the truck's main frame and is referred
to as a "Power Module". This arrangement permits
removal and installation of these components with a
minimum amount of disconnect being made and by uti-
lizing the unique "Roll In/Roll Out" feature.
Although the instructions in this section are primarily
based upon the "Rollout" method for major component
removal, the radiator and fan may be removed as sep-
arate items. Instructions for radiator and fan removal
are contained later in this section.

PREPARATION

The complete power module weighs approximately
36,950 lbs. (16 760 kg). Make sure lifting device to
be used is of an adequate capacity.
1. Position the truck in a work area with a flat, level
surface and adequate overhead clearance to per-
mit raising the dump body.
2. Apply parking brake and block wheels to prevent
truck movement. Raise body and install safety
lock pin and body cable.
Do not work under raised body without first making
sure the body lock pin and body cable is installed.
3. Tag or mark all air lines, oil lines, fuel lines and
electrical connections to assure correct hookup at
time of power module installation. Plug all ports
and cover all hose fittings or connections when
disconnected to prevent dirt or foreign material
from entering.
4. It is not necessary to remove the grille or radiator
prior to the removal of the power module. If radia-
tor removal is desired or if only radiator repair is
necessary, refer to "Cooling System" in this sec-
tion.
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POWER MODULE

Removal

1. Disconnect batteries using the following proce-
dure in this order:
a. Open battery disconnect switch located on
battery equalizer box on deck of truck.
b. Remove battery equalizer GND (-) terminal.
c. Remove +12V (output) terminal at equalizer.
d. Remove +24V (input) terminal at equalizer.
e. Disconnect battery negative (-) terminal at bat-
tery box.
f. Disconnect battery positive (+) terminal.
2. Disconnect hydraulic pump drive shaft (1, Figure
2-4) at the drive shaft U-joint companion flange.
3. Remove main alternator blower duct (Refer to Fig-
ure 2-1):
a. Remove clamps and disconnect power cables
from the rectifier diode and resistor panels (2,
3) located on the rear of the blower intake
duct. Remove cover and disconnect cables
(routed to main alternator) from front side of
transition structure (5).
b. Attach a lifting device to the rear center deck
structure (4), remove attaching hardware and
remove from truck.
c. Remove clamps and disconnect air hose (6) at
electrical cabinet and main alternator.
d. Attach hoist to lifting eyes on blower inlet duct
assembly. Remove hardware attaching duct to
main alternator
attaching upper duct mounts to electrical cabi-
net. Remove hardware attaching duct to deck
at right and left sides.
e. Recheck for any other cables or hoses and lift
duct assembly from the truck. Cover all open-
ings to prevent entrance of foreign material.
Power Module
inlet. Remove hardware
C2-1