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Carga Suspensiones
Carga Suspensiones
Carga Suspensiones
The current methods for checking and adjusting the oiling height and charging height in the front and rear
suspensions may cause inaccurate payload meter calculations due to a wide variation in the weights of
dump bodies used by various customers. Improved suspension oiling and charging procedures have been
developed.
NOTE: Checking and/or adjusting the suspension charging pressures during periodic maintenance
inspections is not recommended. The oiling and charging procedures must be performed on flat ground
and under specific controlled conditions.
CLEANED BY
WIPER SEAL CLEANED BY
WIPER SEAL
DIRT RING
DIRT RING
FRONT SUSPENSION
REAR SUSPENSION
73536
WARNING
All suspensions are charged with compressed nitrogen gas with sufficient pressure to cause injury
and/or damage if improperly handled. Follow all safety instructions, cautions, and warnings provided
in the following procedures to prevent any accidents during servicing and charging.
These procedures cover the suspension oiling and charging of Hydrair® II suspensions on Komatsu
electric drive dump trucks. Suspensions that have been properly charged will provide improved handling
and ride characteristics while also extending the life of the truck frame and improving tire wear.
Inflation pressures and exposed piston lengths are calculated for a normal truck gross vehicle weight
(GVW). Additions to truck weight, such as body liners, tailgates, water tanks, etc, should be considered
part of the payload. Keeping the truck GVW within the specification shown on the grade/speed chart in
the operator cab will extend the service life of the truck main frame and allow the suspensions to produce
a comfortable ride.
For best results, suspensions should be charged in pairs (front suspensions together and rear suspensions
together). If rear suspensions are to be charged, the front suspensions should be charged first. If the truck
lifts off of support blocks before charging is complete, stop charging. If both front and rear suspensions
are serviced, DO NOT remove the front suspension support blocks until after the rear suspensions have
been completely serviced.
Anytime the suspensions are charged, the calibration of the payload meter (PLM) system is affected. To
ensure accurate payload records, perform a "Clean Truck Tare" before returning the truck to operation.
Refer to the payload meter information in the shop manual.
REQUIRED EQUIPMENT
• Hydrair® charging kit
• Jacks and/or overhead crane
• Support blocks for oiling
• Support blocks for charging
• Hydrair® oil (see Specifications Chart)
• Friction modifier (see Specifications Chart)
• Dry nitrogen (see Specifications Chart)
MEASURED
HEIGHT MEASURED
HEIGHT
WARNING
When support blocks are in place, they must be secured with a strap or by other means to avoid
accidental discharge. An unsecured support block could fly loose as weight is applied, presenting the
possibility of serious injury to nearby personnel and/or damage to the equipment. Overhead clearance
may be reduced rapidly and suddenly when nitrogen pressure is released.
4. Position and secure the oiling support blocks 180 degrees apart as shown in Figure 8. When nitrogen
pressure is released, the suspensions will lower and rest on the blocks.
NOTE: Ensure that the blocks do not mar or scratch the plated surfaces of the pistons or damage wiper
seals in the lower bearing retainer. Support blocks must seat on the spindle and the cylinder housing, not
on the capscrew heads.
WARNING
Wear a face mask or goggles. Ensure that only the swivel nut turns. Turning the entire charging valve
body may result in the valve assembly being ejected from the suspension by the gas pressure inside.
84483
Front Suspension
Estimated Charging Pressure
Truck Model Oiling Height Charging Height
(see NOTE below)
730E-7
2 758 kPa (400 psi)
730E-7T
38.1 mm (1.50 in.)
730E-8
2 772 kPa (402 psi)
C 730E-10
830E-1AC
830E-1AT 2 696 kPa (391 psi)
830E-5
228.6 mm (9.00 in.)
860E-1K
3 365 kPa (488 psi)
860E-1KT
930E-4
930E-4SE
2 930 kPa (425 psi)
930E-4AT
25.4 mm (1.00 in.)
930E-5
960E-2K
219.1 mm (8.63 in.) 3 282 kPa (476 psi)
960E-2KT
980E-4
C 980E-5 228.6 mm (9.00 in.)
980E-4AT 3 047 kPa (442 psi)
980E-4 Oil Sands
165.1 mm (6.50 in.)
C 980E-5 Oil Sands
NOTE: Charging pressures are for reference only and may vary depending upon the weight of the
dump body. The charging pressure is provided only as a starting point for obtaining the correct
charging height, which is the critical measurement for a properly charged suspension. The pressure
may be adjusted as necessary to maintain the proper charging height.
WARNING
When support blocks are in place, they must be secured with a strap or by other means to avoid
accidental discharge. An unsecured support block could fly loose as weight is applied, presenting the
possibility of serious injury to nearby personnel and/or damage to the equipment. Overhead clearance
may be reduced rapidly and suddenly when nitrogen pressure is released.
4. Position and secure oiling support blocks (2, Figure 10) in place so the blocks are seated between
main frame (1) and rear axle housing (3). A block should be used on both the left and right sides of
the truck.
WARNING
Wear a face mask or goggles. Ensure that only the swivel nut turns. Turning the entire charging valve
body may result in the valve assembly being ejected from the suspension by the gas pressure inside.
2 73539
WARNING
Be aware that the truck may lower suddenly when releasing nitrogen gas from the suspensions.
13. Slowly release nitrogen gas until the charging heights of both rear suspensions match the charging
height listed in Table 3.
The charging pressure is provided only as a starting point for obtaining the correct charging height.
The pressure may be adjusted as necessary to maintain the proper charging height listed in Table 3.
NOTE: There is no specific charging pressure that must be maintained. The required pressure for
maintaining the charging height will depend upon the weight of the dump body.
14. Close inlet valve (4). Leave outlet valves (3) open for five minutes to allow the pressures in the sus-
pensions to equalize.
15. Ensure that both of the rear suspension cylinders are extended the same distance ± 10 mm (0.39 in.).
If the difference in the extension from side to side exceeds this amount, check the front suspensions
for equal extension. Adjust the front suspensions as necessary.
NOTE: A low left front suspension will cause the right rear suspension to be high. A low right front
suspension will cause the left rear suspension to be high.
16. Close outlet valves (3). Remove the charging kit components. Refer to “Removing the Charging
Kit”.
17. If the charging valve is being reused, tighten swivel nut (2, Figure 9) to 6-11 Nꞏm (5-8 ft lb). Install
the valve cap finger-tight.
If a new charging valve is being used, tighten swivel nut (2) to 15 Nꞏm (11 ft lb), then loosen and
tighten the swivel nut to 15 Nꞏm (11 ft lb). Loosen the swivel nut again and tighten to 6-11 Nꞏm (5-8
ft lb). Install the valve cap finger-tight.
18. Install the protective guard over the charging valve.
19. If the front suspensions were serviced, remove the charging support blocks from the front
suspensions. Floor jacks or an overhead crane may be necessary to raise the truck if the blocks have
become jammed in place.
20. Remove the oiling support blocks from the rear axle housing.
Rear Suspension
Estimated Charging Pressure
Truck Model Oiling Height Charging Height
(see NOTE below)
730E-7
72.6 mm (2.86 in.) 275.8 mm (10.86 in.) 1 420 kPa (206 psi)
730E-7T
730E-8
78.6 mm (3.09 in.) 281.8 mm (11.09 in.) 1 544 kPa (224 psi)
C 730E-10
830E-1AC
830E-1AT 1 186 kPa (172 psi)
830E-5 270.1 mm (10.63 in.)
860E-1K
1 469 kPa (213 psi)
860E-1KT 54.2 mm (2.13 in.)
930E-4
930E-4SE
219.3 mm (8.63 in.) 1 296 kPa (188 psi)
930E-4AT
930E-5
960E-2K
53.7 mm (2.11 in.) 218.8 mm (8.61 in.) 1 351 kPa (196 psi)
960E-2KT
980E-4
C 980E-5
980E-4AT 47.2 mm (1.86 in.) 212.3 mm (8.36 in.) 1 455 kPa (211 psi)
980E-4 Oil Sands
C 980E-5 Oil Sands
NOTE: Charging pressures are for reference only and may vary depending upon the weight of the
dump body. The charging pressure is provided only as a starting point for obtaining the correct
charging height, which is the critical measurement for a properly charged suspension. The pressure
may be adjusted as necessary to maintain the proper charging height.