Power Module; Preparation - Komatsu 930E-2 Shop Manual

The radiator, engine and alternator assemblies are
mounted on a roller equipped subframe which is con-
tained within the truck's main frame and is referred to
as a "Power Module". This arrangement permits re-
moval and installation of these components with a
minimum amount of disconnect 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 component
removal, the radiator and fan may be removed as
separate items. Instructions for radiator and fan re-
moval are contained later in this section. Optional
equipment may be installed on the truck, requiring
additional removal and installation steps not listed.
The procedures outlined in this section of the manual
are general instructions for power module removal and
installation. It may be necessary to perform some
procedures in a different order or use different meth-
ods for component removal and installation, depend-
ing on the lifting equipment available at the mine site.
Prior to removal or repair procedures, it may be nec-
essary to remove the body to provide clearance for
lifting equipment to be used. If body removal is not
required, the body should be raised and the safety
cables installed at the rear of the truck.
Read and observe the following instructions before
attempting any repairs!
• Do not attempt to work in deck area until body
safety cables have been installed.
• Do not step on or use any power cable as a
handhold when the engine is running.
• Do not open any electrical cabinet covers or
touch the retarding grid elements until all shut-
down procedures have been followed.
• All removal, repairs and installation of propul-
sion system electrical components, cables etc.
must be performed by an electrical maintenance
technician properly trained to service the sys-
tem.
• In the event of a propulsion system malfunction,
a qualified technician should inspect the truck
and verify the propulsion system does not have
dangerous voltage levels present before repairs
are started.
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POWER MODULE

After the truck is parked in position for the repairs, the
truck must be shut down properly to ensure the safety
of those working in the areas of the deck, electrical
cabinet and retarding grids. The following procedures
will ensure the electrical system is properly discharged
before repairs are started.

PREPARATION

1. Reduce the engine speed to idle. Place the selec-
tor switch in NEUTRAL and apply the parking
brake. Be certain the parking brake applied indi-
cator lamp in the overhead panel is illuminated.
2. Place the drive system in the REST mode by
turning the Rest switch on the instrument panel
ON. Be certain the REST warning lamp is illumi-
nated.
3. Shut down the engine using the keyswitch. If, for
some reason the engine does not shut down, use
the shutdown switch on the center console.
4. Verify the LINK VOLTAGE lights are OFF. If they
remain on longer than 5 minutes after shutdown,
notify the electrical department.
5. Place the GF Cutout Switch in the CUTOUT
position. (See Figure 3-1, page E3-2, Propulsion
System, for switch location.)
6. Verify the steering accumulators have bled down
by attempting to steer.
7. Bleed down the brake accumulators using the
manual bleed valves on the brake manifold.
8. Open the battery disconnect switches.
Tag or mark all hydraulic 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.
It is not necessary to remove the radiator prior to
the removal of the power module. However, the
coolant must be drained and the piping connected
to the brake cooling heat exchanger removed.
If radiator removal is desired or if only radiator
repair is necessary, refer to "Cooling System" in
this section.
Power Module C2-1