Komatsu 830E-AC Shop Manual page 521

8. Install upper bearing structure (6) onto piston
rod. Secure bearing in place with NEW cap
screws (3) and hardened washers (4). Tighten
cap screws to 678 N-m (500 ft lbs) torque.
NOTE: ALWAYS use new cap screws (3, Figure 2-7)
during assembly. Used cap screws will be stressed
and fatigued because of loads imposed on these cap
screws during operation.
9. Apply a light coating of petroleum jelly to the
seals, wiper and bearings. With suspension
housing in a vertical position, carefully lower the
piston rod and end cap assembly into the bore
of the cylinder housing to its fully retracted posi-
tion
10. Install cap screws and hardened washers (1 &
2) and tighten to 420 N-m (310 ft lbs) torque.
11. Install bottom plug (17, Figure 2-6) and tighten
to 17.5 N-m (13 ft lbs) torque.
12. Install charging valve (5, Figure 2-1) using a
new flat gasket under the large hex (valve
body). Tighten large hex of charging valve to
27.4 N-m (16.5 ft lbs) torque.
13. Install remaining plugs and/or pressure sensor.
14. Pressure test according to instructions on the
following page.
H02026
PRESSURE TEST
After rebuild is complete, suspension assembly
should be tested for leakage.
When pressure testing, suspension must not be
allowed to extend. Assembly must be mounted in
a container that is adequate to prevent piston
extension.
1. Using air or nitrogen, pressurize suspension to
7585 ±1380 kPa (1100 ±200 psi) through the
charging valve and maintain pressure for twenty
(20) minutes minimum.
No leakage is permissible.
2. Release pressure from suspension assembly
and remove from containment structure. Do not
remove charging valve.
3. Install charging valve guard.
4. If suspension is to be stored, install suspension
oil prior to storage. (Refer to Front Suspension
Oiling this section.)
5. Protect exposed chrome surface to prevent
damage during storage and handling.
6. Protect remaining exposed, machined surfaces
with a rust preventive grease.
Front Suspensions H2-11