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Suspension mounting cap screws are specially hard-
ened bolts that meet or exceed Grade 8 specifica-
tions. Replace only with cap screws of correct
hardness. Refer to Komatsu Parts Catalog for correct
part number. Before installation, inspect each cap
screw for any defects. Use only new suspension
mounting hardware every time the suspension is
installed.
5. Attach fork truck or lifting device to suspension
and mount suspension to the truck frame mak-
ing certain shear bar (5, Figure 2-3) is flush with
end of suspension keyway. Install fourteen cap
screws (1, 6, 8) with hardened washers and
nuts. (A flatwasher is used under each cap
screw head and each nut. See Figure 2-4 for
washer installation.) The four bottom holes
tapped into suspension housing require cap
screws (6) with hardened washers, and spacers
(9) only.
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 cap screw head they must be
assembled with the inside diameter radius of the
hole toward the head (punch lip away from head)
to prevent damage to the fillet between cap screw
head and shank. See illustration above.
H2-6
2. Grade 8 Cap Screw
Front Suspensions
6. The suspension mounting cap screws are now
ready for tightening using the Turn-of-the-Nut
Tightening Procedure. After completing the
tightening procedure, continue with Steps 7-10
below.
7. Charge suspension with dry nitrogen to fully
extend suspension piston before installing front
wheel hub and spindle.
8. Install wheel, spindle, and tire according to
instructions in Section G.
9. Service the suspension. For instructions refer to
®
HYDRAIR
II Oiling and Charging Procedure.
10. Install suspension boot and secure with clamp.
TURN-OF-THE-NUT Tightening Procedure
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 cap screws of lesser grade/size.
1. Using a torque wrench of known calibration,
tighten all fourteen cap screws (1, 6, 8, Figure
2-3) to 542 ±54 N-m (400 ± 40 ft lbs) torque.
2. Maintain this torque on the top two corner cap
screws and the bottom outer four cap screws
(item 8, the 4 bottom cap screws with nuts).
3. Loosen the 8 remaining cap screws and then
tighten again using turn-of-the-nut tightening
procedure as follows:
4. For the four, 165 mm (6.5 in.) long cap screws
(1, Figure 2-3) at the upper mount, tighten cap
screws initially to 95 N-m (70 ft lbs) torque;
then advance cap screw head 60° using steps
6-a.) through 6-c.). Refer to Figure 2-5.
H02026
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