Installation Of Hardened Flat Washer - Komatsu 930E-2 Shop Manual

4. Lubricate capscrew threads, capscrew head
seats, washer face, and nut seats with a rust
preventive compound. Approved sources are:
• AMERICAN ANTI-RUST GREASE #3-X
from Standard Oil Division of American Oil
Company.
• RUSTOLENE D grease
from Sinclair Oil Company.
• GULF NORUST #3 from Gulf Oil Company.
• RUST BAN 326 from Humble Oil Company.
• 1973 RUSTPROOF from the Texas Com-
pany.
• RUST PREVENTIVE GREASE-CODE 312
from the Southwest Grease and Oil Com-
pany.
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.
• 5% Molybdenum - Disulphide Grease
High tightening force is required to load front sus-
pension mounting capscrews. Repeated tighten-
ing operations will cause capscrew material to
fatigue and break. DO NOT reuse mounting hard-
ware (capscrews, 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 to meet or exceed Grade 8 specifications.
Replace only with bolts of correct hardness. Refer to
the Komatsu Parts Catalog for correct part number.
Before installation, inspect each capscrew for any
defects and number of punch marks. Replace cap-
screw and related hardware if two punch marks are
evident; do not reuse if any defect is suspected. Hard-
ware showing signs of rust, corrosion, galling or local
yielding on any seat or thread surfaces should be
H02013 2/01
replaced. Replace all suspension mounting hardware,
if the truck was operated with the suspension mounting
in a loose joint condition.
FIGURE 2-4. INSTALLATION OF HARDENED
1. Hardened Flat Washer
NOTE: Special hardened flat washers are punched
during the manufacturing process, therefore when
used under the capscrew head they must be assem-
bled with the inside diameter radius of the hole toward
the head (punch lip away from head) to prevent dam-
age to the fillet between capscrew head and shank.
See illustration above.
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
flatwasher is used under each capscrew head
and each nut.) The four bottom holes tapped into
suspension housing require capscrews (6) with
hardened washers, and spacers (9) only.
6. The capscrews are now ready for tightening using
the "Turn-of-the-Nut" Tightening Procedure de-
scribed on the following page.
NOTE: The "Turn-of-the-Nut" tightening procedure
was developed for high strength capscrews (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
FLAT WASHER
2. Capscrew
H2-3