Komatsu 980E-4 Suspensions

Komatsu 930/980E-4 Suspensions
Suspension Systems Mounting and Charging
Copyright © 2018 Technical Training ELTM0090618E0BK2

Jose L. Rodriguez
Training Instructor Tec.
Epsa Chile
joseluis.rodriguez@epsagroup. com
930/980E-4
930/980E-4 SUSPENSIONS
SUSPENSIONS
Komatsu Shop Manual
● Use the correct manual as

supplied with the new Equipment
● The Material in this course is to

be considered as a supplement to
the Komatsu Shop Manual
● The Shop Manual contains

precise details of all topics
discussed in this training course
which should be considered as
your Core reference document
Technical Training ELTM0090618E0BK2

Slide 2
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS
Course Objectives
After successful completion of this lesson, the student will…..
● Understand how to correctly install Suspensions on the Komatsu 930/980E-4

Rear Dump Truck.
● Learn about operational aspects
● Learn how to make use of the maintenance procedures in the Shop Manual
● Understand the following aspects
Front and Rear Suspension details
Front Suspension Installation Rear
Suspension Installation
Front and Rear Suspension principles of operation
Front Suspension charging and maintenance Rear
Suspension charging and maintenance

Slide 3
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS
Front Suspension
● Forged front suspension Rod diameter
▪ 980E 477mm (17.62”)
▪ 930E 400mm (15.75”)
● Large casting steel mounts
● Extra-length glass filled nylon bearings
● Maximum rod stroke
▪ 980E 303 mm (11.9”)
▪ 930E 328 mm (12.92”)

Slide 4
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS
Rear Suspension
● Rear rod diameter

▪ 980E 374mm (14.75”)
▪ 930E 355mm (14.0”)
● Maximum rear stroke
▪ 980/930E 239mm (9.40”)

Slide 5
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS
Front Suspension, mounting
. Mounting faces must
be clean & flat
(within 0.25mm (0,010”)
. Use “turn of nut”
. Replace hardware
after EACH use.
. Lubricate threads and

faces with 5% Moly
grease
. DO NOT exceed 4 rpm

during torque

Slide 6
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS
980E-4 Front Suspension -- Torque Procedure
Torque all 14 capscrew’s by following the

illustrated sequence and maintain 1000 ft.lbs.
up until the final preload steps.
All fasteners must be individually loosened,
then preloaded one at a time, in sequence,
and according to the chart below, while
maintaining the initial clamping torque on all
adjacent bolts.

Slide 7
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS
930E-4 Front Suspension -- Torque Procedure
Torque all 14 capscrew’s by following the illustrated

sequence and maintain 1000 ft.lbs. up until the final
preload steps
All fasteners must be individually loosened, then

preloaded one at a time, in sequence, and
according to the chart below, whilst maintaining
the initial clamping torque on all adjacent bolts

Slide 8
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS

Slide 9
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS
Front Suspension -- Bolt Torque Principles
Turn of the nut

6 threads / inch
90 deg = 40 thou ( 1mm) 1 rev = 160 thou
40 thou stretch
● Produces a precise tensile stretch

Commencing with
▪ Lubricate threads
▪ Accurate pre-torque
▪ Controlled hardware rotation

Slide 10
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS
Rear Suspension – Mountings
Remove and replace:
Do not exceed 10 tons of effort

Slide 11
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS

Slide 12
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS
Hydrair II Suspension
Rod entry = < volume

= > pressure
● Re-bound control provided by control of Annulus area oil
● Dirt Ring indicates operating stroke of assembly

Slide 15
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS
Hydrair II Suspension
The Hydrair suspension should be considered as a variable volume container filled with a mixture
of none compressible oil to provide lubrication and rebound rate control, and compressible
nitrogen gas for load support and shock absorption.
If we start with a container of a specified volume filled with a gas at a specified pressure, and then
change the volume of the container we will cause a change in the gas pressure in inverse
proportion. The internal volume of the container is varied by how much off the piston rod has
entered into the container
This is precisely what happens when an empty truck is loaded, when empty the containers at the
four corners of the truck will have a volume defined by the measurable rod extension and based on
how much pressure is required to support the force at that corner, F=P/A.
As we increase the load of the truck “F” the piston Rods will enter the suspension housings, thus
reducing the “container” volume and increasing its pressure “P” until this pressure is sufficient to
support the load “F”, note that the supporting area of the suspension “A” is a constant.
The dynamics of the Hydrair suspension conform to the age old gas laws, in this instance Boyles
Law.

Slide 16
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS
Boyles Law -- (P1 V1 = P2 V2)

Slide 17
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS
Hydrair II Principle
EMPTY The heavier the load, the

TRUCK greater the pressure
P = F
A

Slide 18
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS
Boyles Law at Work
V1 = 10 V2 = 5
P1 = 50 P2 = 100
P1.V1 = 500 P2.V2 = 500
P1.V1 = P2.V2
Slide 19
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS

Slide 21
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS
Suspension Charging -- Equipment Bleed off trapped

gas
Secondaryseat
Primary seat

Slide 22
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS
Front Suspension -- Oiling and Gassing
Allow at least 3 hours for gas to separate

before commencing with repairs
OR
Bleed nitrogen pressure with charge kit
Drain old oil, re-fill and set oiling height
Carry out on both sides simultaneously
Slide 23
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS
Front Suspension -- Oiling and Gassing
Always commence at the front of the truck when charging truck suspensions, and work with both simultaneously.
Do Not interfere with the charge state of any suspension unless it shows obvious signs of leakage (external oil) or very
low or high static heights.
The “dirt” ring that develops around the lower exposed portion of the chrome rod is an excellent indicator of suspension
charge, it should be similar to its partner on the opposite side of the truck and it should be three to four times the
specified “oiling” height.
If a suspensions displays signs of sever leakage, re-charging will not solve the problem, it will merely prolong the agony
of effecting comprehensive repairs.
The Oil gas mixture in side the suspension is very difficult to separate, and requires many stationary hours to separate
to an acceptable level, thus if for any reason the Oil level has to be attended to it is most prudent to drain the entire
suspension and start a fresh.
Not only does this accelerate the process it re-vitalizes the assembly by removing all of the abrasive contaminants, in
fact it is a good approach to drain suspensions regardless of there charge state on a yearly basis to extend the service
life of the assembly.
Drain suspensions by taking the weight of the truck, attach the charging kit and vent off the gas pressure, once all
pressure is exhausted, remove the charge valve assembly, then position a suitable liquid container below the
suspension and remove the lower drain plug in the Rod to drain out old oil. repeat this exercise on the opposite side and
then lower the truck onto OIL level blocks as shown in the slide and as per the table.
Replace the lower drain and fill with the recommended suspension fluid to the top of he suspension, lift the truck up from
the Oil blocks and settle the truck back down onto appropriately sized GAS blocks. Note special LOWER charge height
for OIL SANDS OPERATION.
Then install the charge valve, connect the charge kit and adjust the charge kit regulator to the specified charge
pressure. Slowly open the charge taps on the charging manifold and administer the Nitrogen gas gradually to both
suspensions.
Allow the internal pressure to settle at the specified pressure and then close off the delivery, verify that the static
pressure is still correct and then close the charging valve, and remove the charge kit.
It will then most likely be necessary to lift the truck up off of the charge blocks, once clear the blocks can be removed
and the truck lowered to settle on the charged gas.
DO NOT be concerned if the truck adopts an un-even keel, you know that you have charged the suspensions to the
specified heights and pressures, so it must be some external force that is causing the un-levelness.

Slide 24
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS
Rear Suspension Charging – Rod Down Style

Slide 25
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS
Rear Suspension -- Flushing
● Bleed off all nitrogen
● Remove lower drain plug and collect
old oil
● Refill with fresh oil, by filling from the
top point.
Routine (yearly) operation

● Preserves internal components
● Saves time when servicing oil levels
Used Suspension oil, +/- 6000hrs

Slide 27
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS
Rear Suspension -- Correct Oil Level

Slide 28
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS
Subject to 2018 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.
Rear Suspension -- Gas Level
Hoist body to move more mass

onto rear axle

Slide 29
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS
Rear Suspension -- Results when Blocks are Removed
P = F
A

Slide 30
Jose L. Rodriguez
Epsa Chile
930/980E-4
SUSPENSIONS
Rear Suspension -- Blocks Removed

Slide 31
Jose L. Rodriguez
Epsa Chile
Subject to 2018 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.
THE END
Copyright © 2018 Technical Training ELTM0090618E0BK2

Jose L. Rodriguez
Epsa Chile

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What are the objectives of the suspension systems training?

What are the objectives of the suspension systems training?

What are the main components of the front suspension system?

What are the main components of the front suspension system?

Komatsu 930/980E-4 Suspensions

Suspension Systems Mounting and Charging

Copyright © 2018 Technical Training ELTM0090618E0BK2

Komatsu Shop Manual

● Use the correct manual as

● The Material in this course is to

● The Shop Manual contains

Technical Training ELTM0090618E0BK2

After successful completion of this lesson, the student will…..

● Understand how to correctly install Suspensions on the Komatsu 930/980E-4

Technical Training ELTM0090618E0BK2

Technical Training ELTM0090618E0BK2

● Rear rod diameter

Technical Training ELTM0090618E0BK2

. Use “turn of nut”

. Lubricate threads and

. DO NOT exceed 4 rpm

Technical Training ELTM0090618E0BK2

Torque all 14 capscrew’s by following the

Technical Training ELTM0090618E0BK2

Torque all 14 capscrew’s by following the illustrated

All fasteners must be individually loosened, then

Technical Training ELTM0090618E0BK2

Technical Training ELTM0090618E0BK2

Turn of the nut

● Produces a precise tensile stretch

Technical Training ELTM0090618E0BK2

Do not exceed 10 tons of effort

Technical Training ELTM0090618E0BK2

Technical Training ELTM0090618E0BK2

Rod entry = < volume

● Re-bound control provided by control of Annulus area oil

● Dirt Ring indicates operating stroke of assembly

Technical Training ELTM0090618E0BK2

Technical Training ELTM0090618E0BK2

Boyles Law -- (P1 V1 = P2 V2)

Technical Training ELTM0090618E0BK2

EMPTY The heavier the load, the

Technical Training ELTM0090618E0BK2

P1.V1 = 500 P2.V2 = 500

Technical Training ELTM0090618E0BK2

Suspension Charging -- Equipment Bleed off trapped

Technical Training ELTM0090618E0BK2

Allow at least 3 hours for gas to separate

Technical Training ELTM0090618E0BK2

Technical Training ELTM0090618E0BK2

Routine (yearly) operation

Used Suspension oil, +/- 6000hrs

Technical Training ELTM0090618E0BK2

Rear Suspension -- Gas Level

Hoist body to move more mass

Technical Training ELTM0090618E0BK2

Technical Training ELTM0090618E0BK2

Technical Training ELTM0090618E0BK2

Copyright © 2018 Technical Training ELTM0090618E0BK2

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