Komatsu 830E, Shop Manual

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C2-6 Power Module 6/02 C02018
6. Lower the power module to the subframe guide
rails, relax the hoist slightly and roll the power
module into truck frame until lifting chains contact
frame crossmember.
7. Place stands or blocking under front of subframe
to support assembly while repositioning hoist.
8. Install a safety chain around the truck frame and
the front subframe cross member. The safety
chain will prevent the power unit from rolling for-
ward.
9. Place a small block behind each rear subframe
roller to prevent rolling.
10. Lower hoist to allow subframe to rest on stands
and rollers. Remove lifting device.
11. Attach hoist to front lifting eyes on subframe.
12. Remove the small blocks behind the subframe
rollers, remove safety chain, and slowly roll the
power module into position over the main frame
mounts. Lower hoist until front subframe mount is
aligned and seated on the front, main frame
mount. Reinstall safety chain.
13. Relocate hoist to the rear portion of the engine/
alternator cradle structure and raise just enough
to permit removing the subframe rollers.
14. Lower the rear portion of the subframe until the
subframe rubber bushings are seated in the rear
mounting brackets located on the main frame of
the truck.
15. After subframe is seated in frame mounts, the
safety chain may be removed from the front sub-
frame member.
16. Install capscrews (9, Figure 2-4) and lockwashers
in the front mount and tighten capscrews to 220
±22 ft. lbs. (298 ±30 N.m) torque. Install ground
strap between frame and subframe. Reinstall air
dam. Install cover (10) if grille is installed.
17. Install the rear subframe mounting caps (3) and
secure caps in place with lubricated capscrews
(4). Tighten capscrews to 407 ±15 ft. lbs. (551
±21 N.m) torque.
18. Install radiator support struts (12).
19. Install exhaust ducts (1 & 3, Figure 2-2) Install
capscrews (2) washers and nuts to secure ducts
to turbochargers. Install “V” band clamps (5) and
support clamps (4).
20. Connect the cab heater inlet and outlet hoses and
open both valves.
21. Connect the hydraulic pump drive shaft (1, Figure
2-4) to the companion flange on the alternator.
Tighten capscrews to standard torque.
22. Connect wheel motor cooling blower air outlet
hose. Tighten all clamps securely to insure a pos-
itive air seal.
23. Lift main alternator blower intake duct into position
and install hardware at mounts. (Refer to Figure
2-1)
a. Install hardware at transition structure to
blower inlet joint, electrical cabinet, and deck
mounts.
b. Install control cabinet air hose (6), electrical
cables and any other hoses and wiring
removed during power module removal.
c. Lift rear, center deck structure (4) in place and
install hardware.
24. Connect all remaining electric, oil, and fuel lines.
25. Attach hoist to the front center deck and lift into
position. Align the rear center deck mounting
holes with the support structure in front of the
electrical cabinet. Install capscrews and flat wash-
ers. Do not tighten at this time.
26. Align the front center deck, front mounting holes
with both left and right fender supports. Install
capscrews and flat washers. Tighten all deck
mounting capscrews to standard torque values.
27. Install air intake duct supports (2, Figure 2-3).
Install engine air intake ducts (3). Position adjust-
ers of adjacent T-bolt clamps 180° apart. Tighten
clamps securely to insure a positive.
28. Connect the air filter restriction gauge hoses.
29. Connect the batteries as follows:
a. Install battery positive (+) cable.
b. Install battery ground (-) cable.
c. Install battery equ24V (input) terminal.
d. Install equ12V (output) terminal.
e. Install equalizer GND (-) terminal.
f. Close battery disconnect switch.
30. Service radiator and engine with appropriate flu-
ids. Refer to Section “P”, Lubrication and Service ,
for capacity and fluid specifications.