COMPONENT CODE 5A

PARTS & SERVICE (C)

REF NO. AA16120A
DATE July 10, 2017
NEWS Page 1 of 15
This Parts & Service News supersedes the previous issuance dated October 17, 2016. Discard AA16120.
SUBJECT: IMPROVED SUSPENSION OILING AND CHARGING PROCEDURES
PURPOSE: To provide the field with improved methods for checking and adjusting the oiling
height and charging height in the front and rear suspensions.
APPLICATION: Komatsu Electric Drive Dump Trucks:
730E: 32530-32845, A30079 & Up;
730E-8: A40003 & Up;
830E: 31320-32825, A30544 & Up;
830E-AC: A30001 - A30071, A30079 - A30108;
830E-1AC: A30072 - A30078, A30109 - A30850;
830E-1AC: A40851 & Up;
830E-1AT: A40852 & Up;
860E-1KT: A30003 & Up;
860E-1K: A30031 & Up;
930E: 32604-32816, A30019, A30026-A30120;
930E-2: A30012, A30098, A30100, A30121-A30293, A30295-A30303;
930E-2SE: A30183;
930E-3: A30294, A30304 - A30461;
930E-3SE: A30171 - A30389;
930E-4: A30462 & Up;
930E-4AT: A30504 & Up;
930E-4SE: A30587 & Up;
960E-1: A30001, A30003 - A30026;
960E-1K: A30002, A50003 - A50010;
960E-2: A30027 & Up;
960E-2K: A50011 & Up;
960E-2KT: A50028 & Up;
980E-4: A40003 & Up

FAILURE CODE: 5A00Z9

DESCRIPTION:

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.

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Checking for Improper Suspension Charge
During periodic maintenance inspections, check the dirt ring on the exposed portion of each suspension
piston. See Figure 1. The dirt rings of the front suspensions should be approximately the same height as
each other, and the dirt rings of the rear suspensions should be approximately the same height as each
other. Dirt rings that are at significantly different heights may indicate an improperly charged suspension
cylinder.

Dirt ring heights should be similar across a typical fleet of the same truck model. A benchmark dirt ring
height should be established for the truck fleet to help determine suspect suspension cylinders.

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

FIGURE 1. DIRT RING ON SUSPENSION PISTON

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SUSPENSION OILING AND CHARGING PROCEDURES
GENERAL

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)

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HYDRAIR® CHARGING KIT
Assemble the charging kit as shown in Figure 2, and attach it to a container of pure dry nitrogen (8).

Installing the Charging Kit

1. Assemble the charging kit as shown in Figure 2.
2. Remove the protective covers and charging valve caps from the suspensions.
3. Turn "T" handle valves (1, Figure 2) of adapters (2) completely counterclockwise.
4. Ensure that outlet valves (3) and inlet valve (4) are closed (turned completely clockwise).
5. Attach charging valve adapters (2) to each suspension charging valve stem.
6. Turn the swivel nut (small hex) on the charging valve three full turns counterclockwise to unseat the
valve.
7. Turn "T" handle valves (1) clockwise. This will depress the core of the charging valve and open the
gas chamber of the suspension.
8. Open both outlet valves (3).
NOTE: By selective opening and closing of outlet valves (3) and inlet valve (4), suspensions may be
charged separately or together.

FIGURE 2. HYDRAIR CHARGING KIT

1. “T” Handle Valve 5. Regulator Valve (Nitrogen Pressure)
2. Charging Valve Adapter 6. Manifold
3. Manifold Outlet Valves (from gauge) 7. Charging Pressure Gauge (Suspensions)
4. Inlet Valve (from regulator) 8. Dry Nitrogen Gas Container

NOTE: The arrangement of parts may vary from the illustration.

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Removing the Charging Kit
1. Close both outlet valves (3, Figure 2).
2. Turn "T" handle valves (1) counterclockwise to release the charging valve cores.
3. Tighten the swivel nut (small hex) on the charging valve. If a new charging valve is being used,
tighten the swivel nut to 15 N·m (11 ft lb), then loosen and retighten the swivel nut to 15 N·m (11 ft
lb). Loosen the swivel nut again and retighten to 6 N·m (50 in lb).
4. Remove charging valve adapters (2) from the charging valves.
5. Install the charging valve caps and protective covers on both suspensions.

SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS

Before starting the oiling and charging procedures, support blocks must be fabricated to maintain the
correct exposed piston rod extensions. Different support blocks are required for oiling and for charging
because the oiling and charging heights are different. See Table 2 for each of the dimensions.
NOTE: Nitrogen charging support blocks for the rear suspension are not necessary. However, oiling
blocks are necessary to properly set the oiling height.
Exposed piston rod extensions are specified for both oil level and nitrogen charging for Hydrair II
suspensions. These dimensions are listed in Table 2. At the front suspension, measure from the face of the
cylinder gland to the machined surface on the spindle. At the rear suspension, measure from the face of
the cylinder gland to the piston flange. See Figure 3.
Support blocks may be fabricated in various forms. Mild steel materials are recommended. Square stock
or pipe segments at least 25 mm (1 in.) may be used. The blocks must be capable of supporting the weight
of the truck during oiling and charging procedures while avoiding contact with plated surfaces and seals
on the suspension. Refer to Figure 4 for front suspension support block placement and Figure 6 for rear
suspension support block placement.

CHARGING
HEIGHT CHARGING
HEIGHT

FRONT SUSPENSION REAR SUSPENSION 73538

FIGURE 3. MEASURING THE CHARGING HEIGHT

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FRONT SUSPENSIONS
NOTE: The dump body must be empty and resting on the truck frame before performing the following
procedures.
1. Park the truck on a hard, level surface. Place the directional control lever in PARK.
2. Place wheel chocks in front of and behind both sets of rear tires to prevent roll away.
NOTE: Do not place wheel chocks around the front tires. The front tires will roll forward and backward a
small amount as the suspension travels up and down during the suspension charging process.
NOTE: 860E model trucks, which have parking brakes at both the front and rear wheels, must have
hydraulic pressure to disengage parking brakes. The engine must be running and the directional control
lever must be placed in NEUTRAL for this procedure.
3. Throughly clean the charging valve area on top of each front suspension. Remove the protective
covers from the charging valves.

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 4. 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.

SUPPORT SUPPORT
BLOCK BLOCK

73537

FIGURE 4. FRONT SUSPENSION

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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.

5. Discharge the nitrogen pressure from the suspension as follows:

a. Remove valve cap (1, Figure 7) from the charging valve on top of the front suspension.
b. Connect the nitrogen charging kit to the charging valve. Refer to “Installing the Charging Kit”.
c. Turn swivel nut (2) counterclockwise three full turns to unseat the valve seal. Do not turn the
swivel nut more than three turns. Do not turn charging valve body (3).
d. As the nitrogen pressure is released, the suspension should lower slowly and seat solidly on the
support blocks. Remove the nitrogen charging kit. Refer to “Removing the Charging Kit”.

84483

FIGURE 5. CHARGING VALVE

1. Valve Cap 3. Valve Body (Large Hex Nut)
2. Swivel Nut (Small Hex Nut)

6. Remove the top fill plug next to the charging valve.

7. Fill the suspension cylinder with a clean suspension oil mixture (with 6% friction modifier) until the
oil is even with the top of the fill plug hole.
NOTE: As an alternative method, the suspension can be pressure filled from the rod drain port at the
bottom of the cylinder. This would eliminate the 15 minute wait in the following step.
8. Allow the suspension to settle for at least 15 minutes. Add more suspension oil mixture if necessary.
9. Install a new o-ring on the fill plug and install the fill plug.
10. Connect the nitrogen charging kit to the charging valve. Refer to “Installing the Charging Kit”.
11. Charge the suspensions with nitrogen gas to a charging height of approximately 280 mm (11 in.) in
order to accommodate the charging support blocks. Close inlet valve (4, Figure 2).

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12. Remove the oiling support blocks from the suspensions and install the charging support blocks.
Secure the blocks to prevent accidental dislodging.
NOTE: Use caution to prevent damage to plated cylinder surfaces and oil seals when installing the
support blocks.
13. Remove the center hose from the charging valve manifold.
14. Slowly release nitrogen gas until the pressure drops below the estimated charging pressure listed in
Table 1, then close the valve.
15. Install the center hose to manifold (6).
16. Charge the suspensions to the charging height listed in Table 1.
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 1.
Do not use an overcharge of nitrogen to lift the suspensions off the support blocks.
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.
17. Close inlet valve (4). Leave outlet valves (3) open for five minutes to allow the pressures in the
suspensions to equalize.
18. Close outlet valves (3). Remove the charging kit components. Refer to “Removing the Charging
Kit”.
19. If the charging valve is being reused, tighten swivel nut (2, Figure 5) to 6-11 N·m (5-8 ft lb). Install
the valve cap finger-tight.
If a new charging valve is being used, tighten swivel nut (2) to 15 N·m (11 ft lb), then loosen and
tighten the swivel nut to 15 N·m (11 ft lb). Loosen the swivel nut again and tighten to 6-11 N·m (5-8
ft lb). Install the valve cap finger-tight.
20. Install the protective guard over the charging valve.
NOTE: If the rear suspensions are to be serviced at this time, leave the charging support blocks in place
on the front suspensions until after the rear suspensions are completely serviced.

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Table 1: Front Suspension Oiling and Charging Height Dimensions

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)
830E-1AC
2 696 kPa (391 psi)
830E-1AT
228.6 mm (9.00 in.)
860E-1K
3 365 kPa (488 psi)
860E-1KT
930E-4
930E-4SE 25.4 mm (1.00 in.) 2 930 kPa (425 psi)
930E-4AT
960E-2K
A 219.1 mm (8.63 in.) 3 282 kPa (476 psi)
960E-2KT
980E-4 228.6 mm (9.00 in.)
3 047 kPa (442 psi)
980E-4 Oil Sands 165.1 mm (6.50 in.)
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.

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REAR SUSPENSIONS
NOTE: The dump body must be empty and resting on the truck frame before performing the following
procedures.
1. Park the truck on a hard, level surface. Place the directional control lever in PARK.
2. Place wheel chocks in front of and behind both sets of rear tires to prevent roll away.
NOTE: Do not place wheel chocks around the front tires. The front tires will roll forward and backward a
small amount as the suspension travels up and down during the suspension charging process.
NOTE: 860E model trucks, which have parking brakes at both the front and rear wheels, must have
hydraulic pressure to disengage parking brakes. The engine must be running and the directional control
lever must be placed in NEUTRAL for this procedure.
3. Throughly clean the charging valve area near top of each rear suspension. Remove the protective
covers from the charging valves.

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 6) 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.

FIGURE 6. SUPPORT BLOCK INSTALLATION

1. Main Frame 3. Rear Axle Housing
2. Support Block

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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.

5. Discharge the nitrogen pressure from the suspension as follows:

a. Remove valve cap (1, Figure 5) from the charging valve near the top of the rear suspension.
b. Connect the nitrogen charging kit to the charging valve. Refer to “Installing the Charging Kit”.
c. Turn swivel nut (2) counterclockwise three full turns to unseat the valve seal. Do not turn the
swivel nut more than three turns. Do not turn charging valve body (3).
d. As the nitrogen pressure is released, the suspension should lower slowly and the main frame
should seat solidly on the support blocks. Adjust the oiling support blocks to obtain the oiling
height dimension listed in Table 2.
e. Remove the nitrogen charging kit. Refer to “Removing the Charging Kit”.

84483

FIGURE 7. CHARGING VALVE

1. Valve Cap 3. Valve Body (Large Hex Nut)
2. Swivel Nut (Small Hex Nut)

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NOTE: A plastic tube can be used to help bleed off trapped air inside the piston.
6. Remove the vent plug (1, Figure 8), pressure sensor (2) and charging valve (3).
7. Use one of the open ports to fill the suspension cylinder with a clean suspension oil mixture (with
6% friction modifier) until oil weeps from the open ports. Use drip pans and clean all spillage from
the outside of the suspension.
NOTE: As an alternative method, the suspension can be pressure filled from the rod drain port at the
bottom of the cylinder. This would eliminate the 15 minute wait in the following step.
8. Allow the suspension to settle for at least 15 minutes. Add more suspension oil mixture if necessary.
9. Install vent plug (1) and pressure sensor (2) into the suspension cylinder.
10. Install a new O-ring onto charging valve (3) and install it into the suspension cylinder.

2 73539

FIGURE 8. REAR SUPENSION PORTS

1. Vent Plug 3. Charging Valve
2. Pressure Sensor

11. Connect the nitrogen charging kit to the charging valve. Refer to “Installing the Charging Kit”.
12. Charge the suspensions with nitrogen gas to a charging height of approximately 305 mm (12 in.).
Close inlet valve (4, Figure 2).

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 2.
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 2.
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.

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14. Close inlet valve (4). Leave outlet valves (3) open for five minutes to allow the pressures in the
suspensions 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 5) to 6-11 N·m (5-8 ft lb). Install
the valve cap finger-tight.
If a new charging valve is being used, tighten swivel nut (2) to 15 N·m (11 ft lb), then loosen and
tighten the swivel nut to 15 N·m (11 ft lb). Loosen the swivel nut again and tighten to 6-11 N·m (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.

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Table 2: Rear Suspension Oiling and Charging Height Dimensions

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)
830E-1AC
1 186 kPa (172 psi)
830E-1AT
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
960E-2K
A 53.7 mm (2.1 in.) 218.8 mm (8.61 in.) 1 351 kPa (196 psi)
960E-2KT
980E-4
47.2 mm (1.86 in.) 212.3 mm (8.36 in.) 1 455 kPa (211 psi)
980E-4 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.

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OIL AND NITROGEN SPECIFICATIONS CHARTS

HYDRAIR® II OIL SPECIFICATIONS

Ambient Temperature Part No. Approved Sources
Range
VJ3911 Mobilfluid 424 Sunfleet TH Universal Tractor
(need to add Mobil DTE 15M Fluid
6% of Texaco TDH Oil Chevron Tractor Hydraulic
-34.5°C & above AK3761) AMOCO ULTIMATE Fluid Conoco Power Tran III
(-30°F & above) Motor Oil 5W-30 Fluid Petro Canada Duratran
Fluid
Shell Canada Donax TDL
AK4063 Suspension Oil (premixed 5 gallon container
AK4064 with 6% Friction Modifier) 55 gallon container
VJ5925 Emery 2811, SG-CD, Petro Canada Super Arctic
(need to add 5W-30 Motor Oil, 0W-30
6% of Mobil Delvac I, 5W-40 Conoco High Performance
-48.5°C & above AK3761) Synthetic Motor Oil, 5W-30
(-55°F & above) AK4065 Suspension Oil (premixed 5 gallon container
AK4066 with 6% Friction Modifier) 55 gallon container
NOTE: VJ3911 and VJ5925 oils are not compatible and must not be mixed in a suspension.
VJ3911 and VJ5925 oils are supplied in 19 liter (5 gallon) cans.

FRICTION MODIFIER FRICTION MODIFIER Mixing Instructions

(94% Suspension Oil, 6% Friction Modifier)
Part Number Suspension Oil Amount of Friction Modifier
to add
AK3761 1 gallon of suspension oil add 7.7 oz.
(5 gallon container of 5 gallons of suspension oil add 38.4 oz.
100% Friction Modifier) 55 gallons of suspension oil add 3.3 gal.

NITROGEN GAS (N2) SPECIFICATIONS

Property Value
Nitrogen gas used in Nitrogen 99.9% Minimum
HYDRAIR® II suspension Water 32 PPM Maximum
cylinders must meet or exceed
CGA specification G-10.1 for Dew Point -55°C (-68°F) Maximum
Type 1, Grade F Nitrogen Gas Oxygen 0.1% Maximum

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