Komatsu 830E-AC Shop Manual page 117

The radiator, engine and alternator/blower assem-
blies 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 compo-
nents with a minimum amount of disconnect being
made and by utilizing the unique "Roll In/Roll Out"
feature.
Although the instructions in this section are primarily
based upon the "Rollout" method for major compo-
nent removal, the radiator and fan may be removed
as separate items. Instructions for radiator and fan
removal are contained later in this section.
PREPARATION
The complete power module weighs approxi-
mately 16 760 kg (36,950 lbs.). 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
permit raising the dump body.
2. Apply parking brake and block wheels to pre-
vent truck movement. Raise body and install
safety lock pin and body cable.
Do not work under raised body without first mak-
ing sure the body lock pin and body cable is
installed.
3. Tag or mark all oil lines, fuel lines and electrical
connections to ensure correct hookup at time of
power module installation. Plug all ports and
cover all hose fittings or connections when dis-
connected to prevent dirt or foreign material
from entering.
C02027
POWER MODULE
4. It is not necessary to remove the grille or radia-
tor prior to the removal of the power module. If
radiator removal is desired or if only radiator
repair is necessary, refer to Cooling System in
this section.
Removal
1. Disconnect batteries using the following proce-
dure in this order:
a. Open battery disconnect switch located on
battery switch box on top of front bumper.
b. Inside the battery box, identify the battery
ground cables that connect the negative ter-
minals of two batteries to the ground bus bar
in the bottom of the battery box. Disconnect
these ground cables from the negative termi-
nal of each battery.
c. Disconnect the ground cables from below
the battery box.
d. Disconnect the three positive battery cables
from the bus bar outside the battery box.
Also disconnect three wiring harness from
the battery box.
e. Remove mounting cap screws and remove
battery box from front bumper.
2. Follow the steps below to remove main alterna-
tor inlet duct (2, Figure 2-1):
a. Remove
(routed to main alternator) from front side of
transition structure (4). Disconnect air sensor
from left side of inlet duct.
b. Remove clamps and disconnect air hose (6)
at electrical cabinet and transition structure
(3).
c. Remove mounting hardware and remove
transition structure (3).
Power Module
cover and disconnect cables
C2-3