Komatsu 830E Shop Manual page 315

NOTE: If none of the rust preventive greases listed
above are available for field assembly, use one of the
following lubricants:
•
SAE 30 weight oil.
•
3% Molybdenum - Disulphide Grease
MAXIMUM CAPSCREW USAGE
High tightening force is required to load front sus-
pension mounting capscrews. Repeated tightening
operations will cause capscrew material to fatigue
and break. DO NOT reuse mounting hardware (cap-
screws, hardened washers, and nuts) more than
twice after original installation (3 total - see NOTE
below). Replace capscrews, washers and nuts after
third use.
NOTE: The following method is suggested to control
the "3 - Use" maximum:
Punch mark the capscrew heads with a center punch
after each tightening as follows:
Initial Installation ................ No (0) marks.
Second Installation ............ One (1) punch mark.
Third Installation ................ Two (2) punch marks.
Suspension mounting capscrews are specially hard-
ened bolts that meet or exceed Grade 8 specifications.
Replace only with bolts of correct hardness. Refer to
Komatsu Parts Catalog for correct part number. Before
installation, inspect each capscrew for any defects and
number of punch marks. Replace capscrew and
related hardware if two punch marks are evident; do
not reuse if any defect is suspected. Hardware showing
signs of rust, corrosion, galling or local yielding on any
seat or thread surfaces should be replaced. Replace all
suspension mounting hardware, if the truck was oper-
ated with the suspension mounting in a loose joint con-
dition.
5. Attach fork truck or lifting device to suspension
and mount suspension to the truck frame making
certain shear bar (5, Figure 2-3) is flush with end
of suspension keyway. Install fourteen capscrews
(1, 6, 8) with hardened washers and nuts. (A flat-
washer is used under each capscrew head and
each nut. See Figure 2-4 for washer installation.)
The four bottom holes tapped into suspension
housing require capscrews (6) with hardened
washers, and spacers (9) only.
H02016
FIGURE 2-4. HARDENED WASHER INSTALLATION
1. Hardened Washer
NOTE: Special hardened flat washers are
punched during the manufacturing process,
therefore when used under the capscrew head
they must be assembled with the inside diame-
ter radius of the hole toward the head (punch
lip away from head) to prevent damage to the
fillet between capscrew head and shank. See
illustration above.
6. The capscrews are now ready for tightening
using the "Turn-of-the-Nut" Tightening Procedure
described on the following page.
NOTE: The "Turn-of-the-Nut" tightening procedure
was developed for high strength 1 1/2" UNC cap-
screws (grade 8 or better) in this joint application
only. Do not use this tightening method for other
joint types or capscrews of lesser grade/size.
Front Suspensions
2. Grade 8 capscrew
H2-3