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COMPONENT CODE

PARTS & SERVICE


NEWS

5A

REF NO. AA08122


DATE July 8, 2008
(C)

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SUBJECT:

FRONT SUSPENSION INSTALLATION

PURPOSE:

To inform the field of a new installation procedure for front suspensions.

APPLICATION:

Komatsu Electric Drive Dump Trucks:


830E: 31320-32825, A30544 & Up;
830E-AC: A30001-A30071, A30079-A30108;
830E-1AC: A30072-A30078, A30109 & Up

FAILURE CODE:

5A30Z9

DESCRIPTION:

A new front suspension installation procedure has been developed and is outlined in this bulletin. The
new procedure is intended to improve cap screw loading consistency and reliability. Service manuals will
be updated to reflect this change at the next revision.

FRONT SUSPENSION INSTALLATION


1. Remove all paint, rust, dirt and foreign debris
from the suspension mounting surfaces.

3. Inspect the suspension and frame mounting


surfaces for damage or wear. Check for the
following criteria:

Flatness of each surface must be within


0.25 mm (0.010 in.).

Surface finish must not exceed 0.635 m


(250 in.) roughness average (RA),
medium tool cut.

If measurements are not within specifications,


contact your Komatsu customer service manager for further instructions.

FIGURE 1. REMOVING DEBRIS

4. Clean and dry all suspension mounting hardware. Use the same cleaning agent that was
used to clean the mounting surfaces.

2. Clean and dry the mounting surfaces on both


the suspension and the frame. Use a cleaning
agent that does not leave a film after evaporation, such as isopropyl alcohol, acetone or
lacquer thinner.

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.

High tightening torque is required to load the


front suspension mounting cap screws. Repeated
tightening will result in cap screw fatigue and
damage. DO NOT reuse mounting cap screws,
washers and nuts. Replace the hardware after
each use.
Suspension mounting cap screws are specially
hardened to meet or exceed grade 8 specifications. Replace only with cap screws of correct
hardness. Refer to the appropriate parts book for
the correct part numbers.

The use of dry threads in this application is not


recommended. Due to the high tightening forces
required to load these cap screws, dry threads or
threads lubricated with anti-seize compounds
may result in damage. Only use the approved
lubricant specified below.
5. Lubricate the cap screw threads, cap screw
head seats, washer faces and nut seats with
5% molybdenum-disulphide grease.
6. Identify and separate the hardware according
to location on the suspension. Refer to Figure
2.

FIGURE 2. HARDWARE IDENTIFICATION


1. Cap Screw - 1 1/2" - 6NC x 6 1/2" (G8)
2. Flat Washer - 1 1/2" (G8)
3. Nut - 1 1/2" - 6NC (G8)
4. Cap Screw - 1 1/2" - 6NC x 13" (G8)
5. Spacer
6. Shear Key
7. Part Of Frame

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7. The hardened flat washers used on the front
suspensions are punched during the manufacturing process. Assemble the cap screws and
washers and position the punched lip away
from the cap screw head to prevent damage.
Refer to Figure 3.

FIGURE 4. SUSPENSION INSTALLATION


FIGURE 3. FLAT WASHER ORIENTATION
1. Hardened Flat Washer 2. Cap Screw

8. Lift the front suspension into position on the


frame. The weight of each front suspension
cylinder is approximately 2228 kg (4,912 lb).
9. Install the mounting hardware and the shear
key. Install the shear key flush with the side
face of the suspension.
Install one washer under each cap screw head
and one washer under each nut (where applicable).
Initially tighten the hardware to 1356 136
Nm (1000 100 lb ft) in the sequence shown
in Figure 5. Use a properly calibrated torque
wrench to ensure accuracy.
NOTE: Do not exceed 4 rpm tightening speed. Do
not hammer or jerk the wrench while tightening.

FIGURE 5. TIGHTENING SEQUENCE MAP


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The mounting cap screws will now need to be
loosened and then tightened using angle-advance.
The first set of cap screws to be adjusted will be at
the upper mounting joint. The cap screws must be
loosened one at time and then tightened by
advancing a specified rotational degree. Use the
map shown in Figure 5 for proper tightening
sequence.
Upper Mounting Joint - 60 Advance

The proper sequence for the upper mounting joint


is 1-2-3-4-9-10. Refer to Figure 5.
10. Loosen the first cap screw. All other cap
screws must be maintained at 1356 136
Nm (1000 100 lb ft).

14. Make new reference lines along the cap


screw, nut and frame at the rear of the joint as
shown in Figure 7. These reference lines will
be used to verify the cap screws have maintained their torque.
15. Repeat this process in sequence for the
remaining cap screws in the upper mounting
joint.
NOTE: If for any reason these fasteners need to be
checked for tightness after completing this
procedure, loosen and inspect all 14 cap screws
and repeat the entire process. The hardware,
again, must be cleaned and lubricated before
repeating.

11. Tighten the cap screw to 95 Nm (70 lb ft).


NOTE: Do not exceed 4 rpm tightening speed. Do
not hammer or jerk the wrench while tightening.
12. Mark a corner of the cap screw head with a
paint marker as shown in Figure 6. Draw a
reference line on the suspension surface next
to the marked corner on the cap screw. Draw
a reference line on the suspension 60 degrees
in advance of the marked corner on the cap
screw.
FIGURE 7. MAKING REFERENCE LINES

Lower Mounting Joint - 90 Advance

The proper sequence for the lower mounting joint


is 5-6-7-8-11-12-13-14. Refer to Figure 5.

FIGURE 6. 60 DEGREE ADVANCE

16. Loosen the first cap screw. All other cap


screws must remain tightened.
17. Tighten the cap screw to 203 Nm (150 lb ft).

13. Advance the cap screw to the 60 advance


mark. Hold the nut at the rear of the joint stationary while tightening.

AA08122

NOTE: Do not exceed 4 rpm tightening speed. Do


not hammer or jerk the wrench while tightening.

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18. Mark a corner of the cap screw head with a
paint marker as shown in Figure 8. Draw a
reference line on the suspension surface (or
frame) next to the marked corner on the cap
screw. Draw a reference line on the suspension surface (or frame) 90 degrees in advance
of the marked corner on the cap screw.

FIGURE 9. MAKING REFERENCE LINES

FIGURE 8. 90 DEGREE ADVANCE

19. Advance the cap screw to the 90 advance


mark. Hold the nut at the rear of the joint
(where applicable) stationary while tightening.
20. Make new reference lines along the cap
screw, nut and frame at the rear of the joint as
shown in Figure 7. For the four cap screws
with spacers, refer to Figure 9. These reference lines will be used to verify the cap
screws have maintained their torque.
21. Repeat this process in sequence for the
remaining cap screws in the lower mounting
joint.
NOTE: If for any reason these fasteners need to be
checked for tightness after completing this
procedure, loosen and inspect all 14 cap screws
and repeat the entire process. The hardware,
again, must be cleaned and lubricated before
repeating.

Inspection
Visual inspections of the bolted joints are necessary after the truck has been released for use.
Inspect the joints at each front suspension at the
following intervals: 8 hours, 50 hours, 250 hours,
and 500 hours.
If the reference lines on the hardware (Figure 7
and Figure 9) have remained in alignment, the
trucks may remain in use.
If at least one of the cap screws has shown signs of
movement, the truck must be taken out of service.
The suspension mounting cap screws must be
removed, cleaned, and inspected. If any cap
screws have any signs of damage, replace all cap
screws. Install the cap screws again, according to
this installation procedure.

Other Models
For front suspension installation instructions on
other models refer to the following Parts & Service News Bulletins:
730E: AA08121 - Front Suspension Installation
930E related models: AA08123 - Front Suspension Installation

AA08122