Carga Suspensiones PDF

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Producto: TRUCK
Modelo: 773F TRUCK EXD
Configuración: 773F OEM Off-Highway Truck EXD00001-UP (MACHINE)
POWERED BY C27 Engine
Instrucción Especial
Servicing the Suspension Cylinders for Off-Highway Trucks{0756, 7200, 7201, 7201,
7201, 7213, 7213}
Número de medio -REHS4445-00 Fecha de publicación -06/04/2009 Fecha de actualización -06/04/2009
i03546660
Servicing the Suspension Cylinders for Off-Highway Trucks

{0756, 7200, 7201, 7201, 7201, 7213, 7213}
SMCS - 0756-542; 7200-542; 7201-542; 7213-542
Off-Highway Truck:
770 (S/N: BZZ1-UP)
772 (S/N: RLB1-UP)
773F (S/N: EED1-UP)
777F (S/N: JRP1-UP)
Quarry Truck:
775F (S/N: DLS1-UP)
Off-Highway Truck:
773F (S/N: EXD1-UP)
777F (S/N: JXP1-UP)
Introduction
This Special Instruction contains the information and the procedure that should be used for purging the
oil and nitrogen from the suspension cylinders. Also, this document contains an incremental charging
procedure for the oil and nitrogen that is used in the suspension cylinders on off-highway trucks. Read
the entire document before you proceed with any work on the suspension cylinders.
Personal injury or death can result from sudden suspension cylinder

movement.
Sudden movement, up or down, can cause the clearance above your

head to change rapidly.
Read all warning labels on the suspension cylinders before servicing. Do
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773F OEM Off-Highway Truck EXD00001-UP (MACHINE) POWERED BY C27 Engin... Page 2 of 82
not check the oil in the suspension cylinder until all the nitrogen
pressure has been released.
Do not, under any condition, remove valves, cover or plugs from the
cylinder unless the rod is fully retracted and all the nitrogen pressure is
released.
Do not stand under the machine when testing or adjusting the

suspension cylinders.
Personal injury or death can result from improper lifting or blocking.
When a hoist or jack is used to lift any part or component, stand clear
of the area. Be sure the hoist or jack has the correct capacity to lift a
component. Install blocks or stands before performance of any work
under a heavy component.
Approximate weights of the components are shown. Clean all surfaces

where parts are to be installed.
The suspension system on the machines consists of four suspension cylinders. When the suspension
cylinders are charged with the proper amount of oil and nitrogen, the suspension system should provide
an easier ride for the operator.
Note: These procedures are intended to be used in order to maintain the correct suspension cylinder
charge.
Important Safety Information

The following information is an explanation of various labels that are found in this document.
Warnings
The warning label informs the technician that an injury or death can occur as a result of a condition that
may exist.
Notices
A notice informs the technician that component damage can occur as a result of a condition that exists.
Notes
A note contains general information for the technician about the operation that is being performed.
Proper repair is important to the safe operation and the reliable operation of this machine. This
document outlines recommended procedures. Some of the procedures require special tools, devices, or
work methods.
Before you perform any repairs or before you perform any maintenance, read all safety
information. Understand all safety information before you perform any repairs or before you
perform any maintenance.
Safety information is provided in this document and on the machine. If these hazard warnings are not
heeded, bodily injury or death could occur to you or other persons.
The "Safety Alert Symbol" that is followed by a "Signal Word" identifies a hazard. "DANGER",
"WARNING", and "CAUTION" are "Signal Words".
Illustration 1 g00008666
The signal word "WARNING" has the following meanings:
 Pay Attention !
 Become Alert !
 Your Safety Is Involved !
The message that appears under the safety alert symbol explains the hazard.
Operations or conditions that may cause product damage are identified by "NOTICE" labels on the
machine and in the service information.
The person that services the machine may be unfamiliar with many of the systems on the machine. Use
caution when you perform service work. Special knowledge of the systems and of the components is
important. Before you remove any component or before you disassemble any component obtain
knowledge of the system and knowledge of the component.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The safety information in this document and the safety information on the machine are not all
inclusive. You must determine that the tools, procedures, work methods, and operating techniques
are safe. You must determine that the operation, lubrication, maintenance, and repair procedures
will not damage the machine. Also, you must determine that the operation, lubrication,
maintenance, and repair procedures will not make the machine unsafe.
Basic Precautions
Improper operation, lubrication, maintenance or repair of this product

can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on

this product, until you have read and understood the operation,
lubrication, maintenance and repair information.
Always observe the list of basic precautions that follows:
Safety Signs
Safety signs include the items that follow: signs, information plates and decals. Read all "Safety" signs
on the machine before operating, lubricating or repairing the machine. Understand all "Safety" signs on
the machine before operating, lubricating or repairing the machine. Replace any safety signs that are in
the conditions that follow: damage, unreadable and missing.
Protective Equipment
When you work around the machine, always wear protective equipment that is required by the job
conditions. Protective equipment includes the items that follow: hard hat, protective glasses and
protective shoes. In particular, wear protective glasses when you use a hammer or when you use a sledge
hammer. When you weld use the appropriate protective equipment that is required by the job conditions.
Protective equipment for welding includes the items that follow: gloves, welding hood, goggles and
apron. Do not wear loose clothing or jewelry that can catch on parts of the machine.
Mounting and Dismounting
Use steps and handholds whenever you mount the machine. Use steps and handholds whenever you
dismount the machine. Before you mount the machine, clean the step and the handholds. Inspect the step
and handholds. Make all necessary repairs.
Face the machine whenever you mount the machine and whenever you dismount the machine. Maintain
a three-point contact with the step and with handholds.
Note: Three-point contact can be two feet and one hand. Three-point contact can also be one foot and
two hands.
Do not mount a moving machine. Do not dismount a moving machine. Never jump off the machine. Do
not try to mount the machine when you carry tools or supplies. Do not try to dismount the machine
when you are carrying tools or supplies. Use a hand line to pull equipment onto the platform. Do not use
any controls as handholds when you enter the cab or when you exit the cab.
Specifications for Cables, Chains, and Lifting Devices
Use approved cables, chains, and lifting devices in order to lift components. Refer to the manufacturer's
weight's in order to determine the application when you select the following items: cable, chain and
lifting devices. When you lift a component, the lift angle is critical. Refer to the Illustration that follows
in order to see the effect of the lift angle on the working load limit.
Note: The lifting devices that are shown in this publication are not Caterpillar parts.
Note: Ensure that the hooks are equipped with a safety latch. Do not place a side load on the lifting eyes
during a lifting operation.
Lift angles for lifting slings.
(A) The load capacity is 100% of the working load limit for the sling.
(B) The load capacity is 86% of the working load limit for the sling.
(C) The load capacity is 70% of the working load limit for the sling.
(D) The load capacity is 50% of the working load limit for the sling.
Hot Fluids and Parts
To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines,
tubes and compartments.
Be careful when you remove filler caps, breathers and plugs on the machine. Hold a rag over the cap or
plug in order to prevent being sprayed by pressurized liquids. When the machine has just been stopped,
the danger of hot fluids is greater.
Corrosion Inhibitor
Corrosion inhibitor contains alkali. Avoid contact with the eyes. Do not allow corrosion inhibitor to
contact the skin for extended periods of time. Avoid repeated contact with the skin. Do not drink
corrosion inhibitor. In case of contact, immediately wash skin with soap and water. For contact with the
eyes, flush the eyes with large amounts of water for at least 15 minutes. Seek medical attention.
Batteries
Do not smoke when an inspection of the battery electrolyte level is made. Never disconnect any
charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A
spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released
from the electrolyte through the battery outlets. Do not allow battery electrolyte to make contact with the
skin or with the eyes. Battery electrolyte is an acid. In case of contact with battery electrolyte,
immediately wash the skin with soap and water. For contact with the eyes, flush the eyes with large
amounts of water for at least 15 minutes. Seek medical attention.
Pressurized Items
1. Always use a board or a piece of cardboard when you check for a leak. Leaking fluid under
pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death.
A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment
immediately. Seek treatment from a doctor that is familiar with this type of injury.
2. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are
disconnected or removed. Always make sure that all raised components are blocked correctly. Be
alert for possible pressure when you disconnect any device from a system that utilizes pressure.
3. Fuel lines that are damaged and fuel lines that are loose can cause fires. Lubrication lines that are
damaged and lubrication lines that are loose can cause fires. Hydraulic lines, tubes, and hoses that
are damaged can cause fires. Hydraulic lines, tubes, and hoses that are loose can cause fires. Do
not bend or strike high pressure lines. Do not install lines which have been bent or damaged.
Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks. If fluids are
injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is
familiar with this type of injury.
4. Pressure air or water can cause personal injury. When pressure air or water is used for cleaning,
wear a protective face shield, protective clothing, and protective shoes. The maximum air pressure
for cleaning purposes must be below 205 kPa (30 psi). When you use a pressure washer, keep in
mind that the nozzle pressures are very high. The nozzle pressures are frequently above 13790 kPa
(2000 psi). Follow all of the recommended practices that are provided by the manufacturer of the
pressure washer.
Machine Preparation
Before you service the suspension cylinders, the dump body must be empty. Verify that the body is
clean and does not contain any carryback material.
Check for leakage and eliminate leakage at all possible locations. It is difficult to detect a nitrogen leak.
A solution that consists of soap and of water can be used to detect leaks. Make sure that the valve caps
are in place. Make sure that the valve caps are tight.
Ensure that the fuel tank is full of fuel.
Position the machine on level ground. Bring the machine to a smooth gradual stop. A sudden stop will
alter the amount of exposed chrome. A sudden stop will also invalidate the information that is used to
determine if the machine needs to be serviced.
Servicing the Suspension Cylinders for the 770 through the 777
Reference the table below for your truck.
Table 1
Servicing Suspension Cylinders

Model S/N Prefix Page Number
770 (S/N: BZZ) 28-38
772 (S/N: RLB) 28-38
773 (S/N: EED) 17-27
773 (S/N: EXD) 17-27
775 (S/N: DLS) 17-27
777 (S/N: JRP) 5-16
777 (S/N: JXP) 5-16
Conditions for Servicing

Service for the suspension cylinder is recommended when any of the following conditions exist:
 A fault code will be displayed on the Vital Information Management System (VIMS), if the
suspension cylinder is fully compressed.
 Suspension cylinder shows signs of leakage.
 The weight of the truck changes more than 22241 N (5000 lb).
 The ride is rough or the struts are at full extension when the truck is empty.
 The suspension cylinder pressures vary 345 kPa (50 psi) or more in comparison to the other side
when the truck is empty. Refer to ""Machine Preparation" ". Compare the left front to the right
front and the left rear to the right rear. Do not compare the front to the rear.
 The ride height of each cylinder is not within ± 13 mm (± .5 inch) of the estimated height of that
vehicle. This is only for a quick reference.
 These numbers should only be used if there are no records of lengths of the ride height from the
past. Use the recorded data from other similar trucks to charge suspension cylinders, if the data is
available. Refer to ""Machine Preparation" ".
Refer to the Operation and Maintenance Manual, "Maintenance Interval Schedule" in order to check the
suspension cylinders at the correct intervals.
In the analysis of a problem in the suspension cylinders, each cylinder operates as a separate unit. Also,
when the left rear cylinder is low, the right front cylinder will be high due to the shift in vehicle weight.
The same conditions exist for the right rear cylinder and the left front cylinder.
Visual Inspection
A visual inspection of each suspension cylinder is the first step in the analysis of a problem. Make sure
that the machine is on level ground. Do the inspection on an empty machine while the engine is stopped.
Check each suspension cylinder for oil leaks around the seals and around the valves.
Check each suspension cylinder for nitrogen leakage. It is difficult to detect a nitrogen leak. A solution
that consists of soap and of water can be used to detect leaks. Make sure that there is no leakage around
the valve cores and around the valve bodies. Make sure that the valve caps are in place. Make sure that
the valve caps are tightened to the correct torque.
Check for leakage at the O-rings that are located under the manifold and under the pressure sensor.
Check for leakage at the O-rings that are located under the protective plates that are on the head. These
protective plates cover some of the head bolts in order to prevent removal of the head while there is
pressure in the suspension cylinder.
Friction between the rod and the lower wear band may cause a dark stain to appear on the chrome of the
suspension cylinder. This stain does not affect the wear life of the suspension cylinder. You can polish
the chrome in order to remove this stain. Eventually, the wear band should become soaked by oil and by
grease and the blackening should decrease.
777 Front Suspension Cylinder (Purge and Charge)

Perform Testing and Adjusting, "Visual Inspection" before you service the suspension cylinders.
The machine must be on level ground when you inspect the suspension cylinder charge. The truck body
must be empty. Coast the machine to a gentle stop without using the brakes. Check the dimensions of
the front suspension cylinders. Compare these dimensions to the dimensions that were recorded
previously. The suspension height will be different for each machine.
When the front suspension cylinders are properly charged, the left front suspension cylinder will not
show as much of the chrome as the right front suspension cylinder shows. This is due to the weight of
the cab.
Note: Both suspension cylinders must be charged at the same time. If only one suspension cylinder
needs servicing, perform the procedure on both suspension cylinders.
Purge the Suspension Cylinder of Oil and of Nitrogen
773F OEM Off-Highway Truck EXD00001-UP (MACHINE) POWERED BY C27 En... Page 10 of 82
Table 2
Tools Needed
Part Number Description Qty
175-5507 Nitrogen Charging Group 1
175-7410 Nitrogen Charging Fitting Gp 1
1S-8938 Charging Chuck 2
9U-5617 Oil Refill Pump 1
Note: When you work with the 238-9928 Valve As , two 1S-8938 Charging chuck will be needed.

movement.


released.

NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Section A-A
(1) Valve cap
(2) Charging valve
(1) Valve cap
(2) Charging valve
(A) Swivel nut
1. Remove valve caps (1) from the charging valves (2) that are located on each of the front
2. Turn the tee handles on the 1S-8938 Chucks counterclockwise in order to ensure that charging
valves (2) will not open during installation.
3. Install the charging hoses to charging valves (2) with 1S-8938 Chucks .
Note: The charging hoses will be used to drain oil into an approved container.
4. Turn the swivel nut counterclockwise on charging valves (2). This opens charging valves (2) .
5. Turn the tee handles on the 1S-8938 Chucks clockwise. This opens up charging valves (2). This
allows oil and nitrogen to flow through charging valves (2) .
Note: When the suspension cylinders have bottomed completely, leave the chucks in position for
five minutes in order to allow the pressure in the suspension cylinders to equalize.
6. After the pressure has equalized, turn the check valves on the 1S-8938 Chucks counterclockwise.
This closes charging valves (2) .
7. Remove the charging hoses from charging valves (2). Attach the charging hoses to rest of the 9U-
5617 Oil Refill Pump . Place the ends of the charging hoses into an approved container or into the
filler tube of the 9U-5617 Oil Refill Pump . Cycle some oil in order to ensure that the charging
hoses are full of clean oil. Attach the 1S-8938 Chucks to charging valves (2) .
Setting Up For Measurement
(3) Reference line
(4) Top edge of the axle
(5) Reference line
1. Position a steel ruler or a thin strip of sheet metal on both of the suspension cylinders in order to
measure the rod extension. A magnet can be used in order to mount the measuring tool. Possible
magnets include the magnetic plug for the final drive and the magnetic base for a dial indicator.
The measuring tool should extend downward. The measuring tool should be parallel to the
centerline of the suspension cylinder.
2. Create reference line (3) on the steel ruler. Reference line (3) should line up with the top edge of
the axle (4) .
3. Create reference line (5) in order to indicate the guideline for the oil charging procedure.
Reference line (5) should be 12.7 mm (0.50 inch) below reference line (3) .
(6) FT1680 Gauge Block
One FT1680 Gauge Block (6) is required for each suspension cylinder. FT1975 Gauge Block (6) may
also be used. These gauge blocks are required for correct service of the front suspension cylinders.
Measure the difference between the outside ambient temperature and the temperature of the service
shop. If this temperature difference is greater than 11°C (20°F), you will also need to use shims. Add 5.1
mm (0.20 inch) of shims for each 5.5°C (10°F) of temperature difference.
Example
Note: Estimate the temperature difference to the nearest 5.5°C (10°F).
Temperature of the service shop ... 10°C (50°F)
Outside ambient temperature ... −40°C (−40°F)
Difference in temperatures
10°C (50°F) − (−40°C (−40°F)) = 50°C (90°F)
Shim thickness:
50°C (90°F) × 5.1 mm (0.20 in) ÷ 5.5°C (10°F) = 46.4 mm (1.80 in)
Dimension for the nitrogen charging procedure
170.0 mm (6.69 in) + 46.4 mm (1.80 in) = 216.4 mm (8.48 in)
Oil Charging Procedure
Table 3
Tools Needed
8T-5320 Hydraulic Test Group 1
1S-8938 Charging Chucks 2
Note: Use SAE 10W oil with the current service classification for the oil charging procedure.

movement.


released.

Note: Ensure that the cylinders have been purged of nitrogen and oil.
Note: The collapsed rod length is 3 mm (0.120 inch).
Typical view of the retarder control and secondary brake valve on the 777
Note: The pressure tap is located on the steering disable valve on the 770 and the 772 truck.
1. Connect the charging hose to the 1S-8938 Chucks .
Note: Construct an appropriate charging hose from the 8T-5320 Hydraulic Test Group .
2. Connect charging hose to the pressure tap. Refer to Illustration 10 in order to view the location of
the pressure tap. The valve for the retarder control and secondary brake valve is located on the
frame inside the left front strut.
3. Connect 1S-8938 Chucks to charging valves (2) .
4. Start the machine.
5. Apply the manual retarder.
7. Turn the tee handle on the 1S-8938 Chucks clockwise. This opens up charging valves (2) .
8. Inject the oil into the suspension cylinder until the correct reference dimension is reached. The
reference dimension was determined in the ""Setting Up For Measurement" " section in this
manual.
Note: If necessary, bleed the air from the oil by opening the second charging valve (2) and add oil
until oil flows through the second charging valve (2) without air in order to ensure proper
performance of the cylinder.
9. Turn the tee handles on the 1S-8938 Chucks counterclockwise. This closes charging valves (2) .
10. Disengage the manual retarder.
11. Shut down the machine.
Note: After the charge pressure has returned to zero, use quick couplers to remove the charging
hoses.
Oil Charging Procedure That Uses The Optional 9U-5617 Oil

Refill Pump
Table 4
Tools Needed
Qty Part Number Description
1 9U-5617 Oil Refill Pump
2 1S-8938 Charging Chucks

movement.


released.

Typical view of the setup for the oil charging procedure
(3) Reference line
(4) Reference line on the cylinder
(5) Reference line for the oil charging procedure
(6) Reference line for the nitrogen charging procedure
Note: Use SAE 10W oil with a service classification of CH for the oil charging procedure.
1. The charging hoses and the 1S-8938 Chucks should be connected to charging valves (2). Open the
shutoff valves. Adjust the air pressure on the regulator. The air pressure must not exceed 860 kPa
(125 psi).
2. Turn the check valves on the 1S-8938 Chucks clockwise. This opens up charging valves (2) .
3. Turn swivel nut (A) counterclockwise. This opens up charging valves (2) .
4. Inject the oil into the suspension cylinder until reference line (5) lines up with the bottom edge of
the rod (4) .
5. Close the shutoff valves. Turn off the air pressure at the regulator. Turn the check valves on the
1S-8938 Chuck counterclockwise. This closes charging valves (2) .
6. Turn swivel nut (A) clockwise. This closes charging valves (2) .
Note: If one suspension cylinder reaches reference line (5) before the other suspension cylinder,
close the shutoff valve for that suspension cylinder. Continue injecting oil into the other
suspension cylinder until the bottom edge of the rod (4) lines up with reference line (5) .
7. After the pressure has returned to zero, use the quick couplers to remove the charging hoses. If the
quick couplers are not available, you may need to remove the 1S-8938 Chucks .
Nitrogen Charging Procedure

Table 5
Tools Needed
FT-1680 Gauge Blocks 2
Dry nitrogen is the only gas approved for use in the suspension
cylinders. Charging the suspension cylinders with oxygen gas will cause
an explosion. This danger will not happen if nitrogen cylinders with
standard CGA (Compressed Gas Association, Inc.) Number 580
Connections are used.
When you order nitrogen gas, be sure that the cylinders are equipped
with CGA No. 580 Connections. Do not use color codes or other
methods of identification to tell the difference between nitrogen
cylinders and oxygen cylinders.
Never use an adapter to connect your nitrogen charging group to a

valve outlet used on both nitrogen, oxygen or other gas cylinders. Be
sure you use dry nitrogen (99.8% purity).
1. Attach the 175-5507 Nitrogen Charging Group and the 175-7410 Nitrogen Charging Fitting Gp to
the quick couplers or to charging valves (2) at each suspension cylinder.
Note: To prevent oil flow into the charging hoses, do not open charging valves (2) at this time.
2. Adjust the nitrogen regulator in order to provide 2760 kPa (400 psi).
4. Turn the tee handles on the 1S-8938 Chuck clockwise. This opens up charging valves (2). This
allows nitrogen to flow to charging valves (2).
5. Open the shutoff valves in order to allow nitrogen to flow to the 1S-8938 Chuck .
NOTICE
To protect the wiper seals on the front suspension cylinders from
damage when the gauge blocks are inserted, make sure the gauge
blocks include the chamfer.
6. Allow nitrogen into the suspension cylinder until gauge block (6) and any required shims can be
inserted between the axle and the suspension cylinder.
7. Lower the nitrogen pressure until the housing for the strut is setting on gauge block (6) .
Note: If one suspension cylinder has extended to the correct amount before the other suspension
cylinder, close the shutoff valve for that suspension cylinder. Continue allowing nitrogen into the
other suspension cylinder until the correct extension has been reached.
8. Turn the tee handles on the 1S-8938 Chuck counterclockwise.
9. Turn the swivel nut clockwise on charging valves (2). This closes charging valves (2) .
10. Remove the 175-5507 Nitrogen Charging Group and the 175-7410 Nitrogen Charging Fitting Gp .
11. Install valve caps (1) to charging valves (2) .
12. Torque valve caps (1) to 2 to 3 N·m (18 to 26 lb in).
13. Start the engine.
14. In order to remove gauge blocks (6), raise the truck body and turn the steering wheel so that the
front wheels move. The suspension cylinders should raise. When the suspension cylinders are not
resting on gauge blocks (6), remove gauge blocks (6) .
15. Operate the machine through a load cycle and a dump cycle.
16. Verify that the correct exposed rod dimension is achieved. The correct amount of exposed rod is
216 mm (8.50 inch) plus any required shims.
17. Record this measurement. Use these recorded measurements as a reference when you inspect the
front suspension cylinders for the correct ride height.
Note: When the suspension cylinders are properly charged, the left front suspension cylinder will
not show as much of the rod as the right front suspension cylinder shows. This is due to the
weight of the cab.
Note: The front suspension cylinders on the 770 and the 772 trucks will have the same amount of
exposed cylinder rod. This is due to the center mounted cabs.
Worksheets
Table 6
Model Of The Machine Date

Serial Number Service Meter Hours
Component Damage
Table 7
Front Suspension Cylinders

Left Right
Oil Leaks
Nitrogen Leaks
Pin to Pin Dimension (1)
(1) This is the dimension between the center of the top mounting pin to the center of the lower mounting pin.
Table 8
Temperature Compensation
Temperature In The Service Shop

Outside temperature
Temperature Difference
Added Length For Temperature Compensation (1)
(1) If the temperature difference is greater than 11°C (20°F), multiply the temperature difference by 2.54 mm (0.10 inch).
Then, divide this amount by 5.5°C (10°F).
777 Rear Suspension Cylinder (Purge and Charge)

Perform Testing and Adjusting, "Visual Inspections" before you service the suspension cylinders.
must be empty. Coast the machine to a gentle stop without using the brakes. Check the dimensions of
the rear suspension cylinders. Compare these dimensions to the dimensions that were recorded
previously. The suspension height will be different for each machine.

Table 9
Tools Needed

movement.


released.

NOTICE
containing fluids.

(1) Valve cap
(2) Charging valve
(1) Valve cap
(2) Charging valve
(A) Swivel nut
1. Remove valve caps (1) from the charging valves (2) that are located on each of the rear
suspension cylinders. Turn the tee handles on the 1S-8938 Chuck counterclockwise in order to
ensure that charging valves (2) will not open during installation.
2. Install the charging hoses to charging valves (2) with 1S-8938 Chuck . The charging hoses will be
used to drain oil into an approved container.
3. Turn the swivel nut counterclockwise on charge valve (2). This opens charge valve (2.) .
Note: The valve core is to aid in charging. The valve core is intended as a safety backup for
charging valve (2). The valve core is not intended as a primary seal. The swivel nut must be in a
closed position prior to attaching the apparatus that is used for charging.
4. Turn the tee handle on the 1S-8938 Chuck clockwise in order to allow nitrogen to flow through
charging valves (2) .
Note: When the suspension cylinders have bottomed completely, leave the chucks in position for
five minutes in order to allow pressure in the cylinders to equalize.
5. After the pressure has equalized, turn the check valves on the 1S-8938 Chucks counterclockwise.
This closes charging valves (2) .
6. Remove the charging hoses from charging valves (2). Attach the charging hoses to the rest of the
9U-5617 Oil Refill Pump . Place the ends of the charging hoses into an approved container or into
the filler tube of the 9U-5617 Oil Refill Pump . Cycle some oil in order to ensure that the charging
hoses are full of clean oil. Attach the 1S-8938 Chucks to charging valves (2) .
Determining Correct Pin to Pin Dimension
Pin to pin dimension
1. Verify the collapsed pin to pin dimension of 915 mm (36 inch). Position a steel ruler or a thin strip
of sheet metal on both of the suspension cylinders in order to measure the rod extension. A
magnet can be used in order to mount the measuring tool. Possible magnets include the magnetic
plug for the final drive and the magnetic base for a dial indicator. The measuring tool can also be
mounted with the clamps that are used to mount the dust boot. The measuring tool should extend
downward. The measuring tool should be parallel to the centerline of the suspension cylinder.
Note: Measure the outside ambient temperature and the temperature of the service shop. If this
temperature difference is greater than 20°F, you will need to adjust the final pin to pin dimension
of 1030 mm (40.5 inch). Add 2.54 mm (0.10 inch) to the pin to pin dimension for each 10°F of
temperature difference.
Example
10°C (50°F) − (−40°C (−40°F)) = 50°C (90°F)
Additional length for temperature compensation
50°C (90°F) × 2.54 mm (0.10 in) ÷ 5.5°C (10°F) = 23.1 mm (.90 in)
Corrected guidelines for the nitrogen charging procedure
1030 mm (40.5 in) + 23.1 mm (0.90 in) = 1053.1 mm (41.43 in)

Table 10
Tools Needed
9U-5617 Oil Refill Pump (1) 1
1S-8938 Charging Struts 2
(1) This is optional.

movement.


released.

Pressure tap for the rear brake slack adjuster
1. Ensure that the cylinders have been purged of nitrogen and oil. The collapsed pin to pin dimension
is 915 mm (36 inch).
Note: Assemble an appropriate charging hose from the 8T-5320 Hydraulic Test Group .
2. Connect the charging hose to the 1S-8938 Chucks .
3. Connect charging hose to the pressure tap for the rear brake adjuster. Refer to Illustration 17 in
order to view the location of the pressure tap. The slack adjuster is located on top of the rear axle
housing.
4. Connect 1S-8938 Chucks to charging valve (2) .
7. Turn the tee handle on the 1S-8938 Chucks clockwise. This opens charging valve (2) .
8. Turn the swivel nut counterclockwise on charge valve (2). This opens charge valve (2) .
9. Inject oil into the suspension cylinder until the correct pin to pin dimension is reached. If
necessary, open the second charging valve (2) and add oil until oil flows through the second
charge valve (2) without air. The correct pin to pin dimension is 1030 mm (40.5 inch) prior to any
required adjustments due to temperature.
10. Turn the tee handles on the 1S-8938 Chucks counterclockwise. This closes charging valves (2) .
11. Turn the swivel nut clockwise on charge valve (2). This closes charge valves (2) .
14. After the charge pressure has returned to zero, use the quick couplers to remove the charging
hoses.

Refill Pump
Table 11
Tools Needed
2 1S-8938 Chucks

movement.


released.
Typical example of the setup for the oil charging procedure
Correct oil level
(3) Reference line
(125 psi).
3. Inject the oil into the suspension cylinder until reference line (5) lines up with reference line (4)
on the cylinder.
suspension cylinder until the reference line (4) on the cylinder lines up with reference line (5) .
5. Turn swivel nut (A) clockwise. This closes charging valves (2) .

Table 12
Tools Needed

Typical example of the setup for the nitrogen charging procedure
the quick couplers or to the charging valves at each suspension cylinder.
Note: To prevent oil flow into the charging hoses, do not open the charging valves at this time.
2. Open the shutoff valves in order to allow nitrogen to flow to the 1S-8938 Chucks .
allows nitrogen to flow to charging valves (2) .
The correct pressure is 2020 kPa (293 psi).
5. Turn the swivel nut counterclockwise. This opens charging valves (2) .
6. Allow nitrogen into the suspension cylinder until the correct pin to pin dimension is achieved. The
correct pin to pin dimension is 1030 mm (40.5 inch).
7. After the suspension cylinders have extended to the proper length, close both of the shutoff
valves.
8. Turn the tee handles on the 1S-8938 Chucks counterclockwise.
9. Turn the swivel nut clockwise on charge valve (2). This closes charging valves (2) .
10. Turn off the nitrogen pressure at the supply tank. Remove the 175-5507 Nitrogen Charging Group
and the 175-7410 Nitrogen Charging Fitting Gp .
11. Install the valve caps to the charging valves. Torque the valve caps to 2 to 3 N·m (18 to 26 lb in).
12. After the suspension cylinders have been properly charged, measure the pin to pin dimension.
Record this value. Use these recorded dimensions as a reference when you inspect the rear
13. Operate the machine through a cycle and check the ride height. If the ride height has changed,
adjust the nitrogen pressure until the correct ride height is reached. Record the final ride height
and pressure.
Worksheets
Table 13

Component Damage
Table 14
Rear Suspension Cylinders

Left Right
Oil Leaks
Nitrogen Leaks
Table 15

Outside Temperature
(1) If the temperature difference is greater than 11° C (20° F), multiply the temperature difference by 2.54 mm (0.10 inch).
773 and 775 Front Suspension Cylinder (Purge and Charge)

must be empty. Coast the machine to a gentle stop without using the brakes.
the cab.
Check the Height of the Front Suspension Cylinders

1. Measure the height of both front suspension cylinders.
2. Record the measured height of both front suspension cylinders.
3. Compare the current recorded height of the front suspension cylinders to the previous recorded
height of the front suspension cylinders.
Note: The suspension height will be different for each machine.

Table 16
Tools Needed
Note: When you work with the 238-9928 Valve As and two 1S-8938 Charging chuck will be needed.

movement.


released.

NOTICE
containing fluids.

(1) Valve cap
(2) Charging valve
(1) Valve cap
(2) Charging valve
(A) Swivel nut
1. Remove valve caps (1) from the charging valves (2) that are located on each of the front
2. Turn the tee handles on the 1S-8938 Chucks counterclockwise in order to ensure that charging
3. Install the charging hoses to charging valves (2) with the 1S-8938 Chucks . The charging hoses
will be used to drain oil into an approved container.
4. Turn the swivel nut counterclockwise on charging valves (2). This opens up charging valves (2) .
allows oil and nitrogen to flow through charging valves (2). When the suspension cylinders have
bottomed completely, leave the chucks in position for five minutes in order to allow the pressure
in the suspension cylinders to equalize.
(3) Reference line
(5) Reference line
the axle (4) .
One FT1680 Gauge Block (6) is required for each suspension cylinder. These gauge blocks are required
for correct service of the front suspension cylinders.
Example
Note: Estimate the temperature difference to the nearest (10°F).
Temperature of the service shop ... (50°F)
Outside ambient temperature ... (−40°F)
10°C (50°F) − (−40°C (−40°F)) = 50°C (90°F)
Shim thickness:
50°C (90°F) × 3.2 mm (0.125 in) ÷ 5.5°C (10°F) = 29.1 mm (1.125 in)
170.0 mm (6.69 in) + 29.1 mm (1.125 in) = 199.1 mm (7.81 in)

Table 17
Tools Needed


movement.


released.

1. Ensure that the cylinders have been purged of nitrogen and oil. The collapsed rod length is 17.2
mm (0.68 inch).
Pressure tap on the retarder control and secondary brake valve
Note: Construct an appropriate charging hose from the 8T-5320 Hydraulic Test Group . Connect
the charging hose to the 1S-8938 Chuck .
2. Connect charging hose to the pressure tap. Refer to Illustration 25 in order to view the location of
the pressure tap. The retarder control and secondary brake valve is located on the frame inside the
left front strut.
3. Connect 1S-8938 Chuck to charging valve (2) .
6. Turn the tee handle on the 1S-8938 Chuck clockwise. This opens up charging valves (2) .
7. Turn the swivel nut counterclockwise on charging valve (2). This opens charging valves (2) .
8. Inject oil into the suspension cylinder until the correct reference dimension is reached. The
reference dimension was determined in the ""Setting Up For Measurement" " section.
If necessary, bleed the air from the oil by opening the second charging valve (2) and add oil until
oil flows through the second charging valve (2) without air in order to ensure proper performance
of the cylinder.
9. Turn tee handles on the 1S-8938 Chuck counterclockwise. This closes charging valves (2) .
10. Turn the swivel nut clockwise on charging valve (2). This closes charging valves (2) .
Note: After the charge pressure has returned to zero, use the quick couplers to remove the
charging hoses.

Refill Pump
Table 18
Tools Needed

movement.


released.

Correct oil level
(3) Reference line
(125 psi).
3. Turn the swivel nut counterclockwise on charging valve (2). This opens charging valves (2) .
on the cylinder.
6. Turn the swivel nut clockwise. This closes charging valves (2) .

Table 19
Tools Needed
FT-1680 Gauge Block 2

2. Adjust the nitrogen regulator in order to provide 3620 kPa (525 psi) for the 773F and 3720 kPa
(540 psi) for the 775F.
4. Open the shutoff valves in order to allow nitrogen to flow to the 1S-8938 Chucks .
NOTICE
5. Allow nitrogen into the suspension cylinder until gauge block (6) and any required shims can be
inserted between the axle and the suspension cylinder. Lower the nitrogen pressure until the
housing of the strut is resting on gauge block (6) .
6. Turn the tee handles on the 1S-8938 Chucks counterclockwise.
7. Turn the swivel nut clockwise on charging valves (2). This closes charging valves (2) .
9. Install valve caps (1) on charging valves (2) .
10. Tighten valve caps (1) to a torque between 2 N·m (18 lb in) to 3 N·m (27 lb in).
12. In order to remove gauge blocks (6), raise the truck body and turn the steering wheel so that the
front wheels move. The suspension cylinders should raise. When the suspension cylinders are not
resting on gauge blocks (6), remove gauge blocks (6) .
13. Operate the machine through a load and a dump cycle.
14. Verify that the correct exposed exposed rod dimension is achieved. The correct amount is 170 mm
(6.7 inch) plus any required shims. Record this measurement. Use these recorded measurements as
a reference when you inspect the front suspension cylinders for correct ride height.
Note: When the front suspension cylinders are properly charged, the left front suspension cylinder
will not show as much of the rod as the right front suspension cylinder. This is due to the weight
of the cab.
Operate the machine for several load cycles after the machine has been properly charged. Some of the
exposed chrome length will be clean because of the wiper seals. Measure this length for each suspension
cylinder. Record this measurement. Use these recorded dimensions as a reference when you inspect the
front suspension cylinder.
The normal height of a charged suspension cylinder will be less than the height of the gauge block.
the cab.
Worksheets
Table 20

Component Damage
Table 21

Left Right
Oil Leaks
Nitrogen Leaks
Table 22
Outside Temperature
773 and 775 Rear Suspension Cylinder (Purge and Charge)

must be empty. Coast the machine to a gentle stop without using the brakes.
Check the Height of the Rear Suspension Cylinders

1. Measure the height of both rear suspension cylinders.
2. Record the measured height of both rear suspension cylinders.
3. Compare the current recorded height of the rear suspension cylinders to the previous recorded
height of the rear suspension cylinders.
Note: The suspension height will be different for each machine.

Table 23
Tools Needed
Note: When you work with the 238-9928 Valve As and the two 1S-8938 Chucks will be needed.

movement.


released.

(1) Valve cap
(2) Charging valve
(1) Valve cap
(2) Charging valve
(A) Swivel nut
2. Turn the tee handles on the 1S-8938 Chuck counterclockwise in order to ensure that the charging
3. Install the charging hoses to charging valves (2) with 1S-8938 Chuck . The charging hoses will be
used to drain oil into an approved container.
NOTICE
containing fluids.

4. Turn the swivel nut counterclockwise on charging valve (2). This opens charging valve (2) .
Note: The valve core is to aid in charging. The valve core is intended as a backup safety for
charging valves (2). The valve core is not intended as a primary seal. The swivel nut must be in
the closed position prior to attaching the apparatus that is used for charging.
5. Turn the tee handle on the 1S-8938 Chuck clockwise in order to allow nitrogen to flow through
charging valves (2). When the suspension cylinders have bottomed completely, leave the chucks
in position for five minutes in order to allow the pressure in the suspension cylinders to equalize.
Determining Correct Pin to Pin Dimension
Pin to pin dimension
1. Verify the collapsed pin to pin dimension of 887 mm (34.9 inch).
2. Measure the difference between the outside ambient temperature and the temperature of the
service shop. Refer to the ""Oil Charging Procedure" " section, if the temperature difference is
less than (20° F).
3. If this temperature is greater than (20° F), you will need to adjust the final pin to pin dimension of
1015 mm (40 inch). Add 2.54 mm (0.100 inch) to the pin to pin dimension for every (10° F) of
temperature difference.
Note: Estimate the temperature difference to the nearest (10° F).
Example
Temperature of the service shop ... 50° F
Outside ambient temperature ... -40° F
Difference in temperature ... (50° F) - (-40° F) = 90° F
Additional length for the temperature compensation ... (90° F * .10 in) / 10° F = .90 in
Corrected guidelines for the nitrogen charging procedure ... 1015 mm + 23.1 mm (.90 in) =
1038.1 mm (40.87 in)

Table 24
Tools Needed

movement.


released.

Note: Ensure that the cylinders have been purged of nitrogen and oil. The collapsed pin to pin
dimension is 887 mm (34.9 inch).
Rear brake slack adjuster
Note: Assemble an appropriate charging hose from 8T-5320 Hydraulic Test Group .
1. Connect the charging hose to 1S-8938 Chuck .
2. Connect charging hose to the pressure tap on the rear brake slack adjuster. Refer to Illustration 32
in order to view the location of the pressure port. The slack adjuster is located on top of the rear
axle housing.
3. Connect 1S-8938 Chuck to charging valves (2) .
6. Turn the tee handle on 1S-8938 Chuck clockwise. This opens up charging valves (2) .
7. Turn swivel nut (A) counterclockwise. This opens up charging valve (2) .
8. Inject oil into the suspension cylinder until the correct pin to pin dimension is reached. The correct
pin to pin dimension 1015 mm (40 inch) prior to any required adjustments from temperature
If necessary, bleed the air from the oil by opening the second charging valve (2) and add oil until
oil flows through the second charging valve (2) without air in order to ensure proper performance
of the cylinder.
9. Turn the tee handle on the 1S-8938 Chuck counterclockwise. This closes charging valve (2) .
10. Turn swivel nut (A) clockwise. This closes charging valve (2) .
hoses.

Refill Pump
Table 25
Tools Needed

movement.


released.

Correct oil level
(3) Reference line
(125 psi).
3. Turn swivel nut (A) counterclockwise. This opens up charging valves (2) .
on the cylinder.
6. Turn swivel nut (A) clockwise. This shuts charging valves (2) .

Table 26
Tools Needed
175-7410 Auxiliary Fitting Group 1

Example of a typical setup for the nitrogen charging procedure
charging valves (2) at each suspension cylinder.
3. Open the shutoff valves in order to allow nitrogen to flow to the 1S-8938 Chucks . Turn the tee
handles on the 1S-8938 Chucks clockwise. This opens up charging valves (2). This allows
nitrogen to flow to charging valves (2) .
valves. Turn the tee handles on the 1S-8938 Chucks counterclockwise.
5. Turn the swivel nut clockwise on charge valve (2). This closes charging valves (2) .
6. Turn off the nitrogen pressure at the supply tank.
8. Install valve caps (1) on charge valve (2) .
9. Tighten valve caps (1) to a torque of 2 N·m (18 lb in) to 3 N·m (27 lb in).
Record this value. Use this recorded value as a reference when the rear suspension cylinders are
inspected.
11. Operate the machine through a cycle and check the ride height. If the ride has changed, adjust the
nitrogen pressure until the correct ride height is reached. Record the final ride height and pressure.
Note: The left and right pressures may not be exactly equal. Typically, pressures will be within
150 kPa (22 psi) of each other on the rear. Ride heights may vary 10 mm (0.4 inch).
Worksheets
Table 27

Component Damage
Table 28

Left Right
Oil Leaks
Nitrogen Leaks
Table 29
Outside Temperature
(1)
If the temperature difference is greater than 11° C (20° F), multiply the temperature difference by 2.54 mm (0.10 inch).
770 and 772 Front Suspension Cylinder (Purge and Charge)

must be empty. Coast the machine to a gentle stop without using the brakes. Take note of the current
ride height of the suspension cylinders. Look up the dimensions for the previous ride height of the
suspension cylinders after the last nitrogen charging procedure. Compare the two values.

Table 30
Tools Needed
Note: When you work with the 238-9928 Valve As and two 1S-8938 Charging Chucks will be needed.

movement.


released.

NOTICE
containing fluids.

(1) Valve cap
(2) Charging valve
(1) Valve cap
(2) Charging valve
(A) Swivel nut
1. Remove valve caps (1) from charging valves (2) that are located on each of the front suspension
cylinders. Install the charging hoses to charging valves (2) with the 1S-8938 Chucks . The
charging hoses will be used to drain oil into an approved container.
2. Turn the swivel nut clockwise on the charging valves (2). This opens up charging valves (2).
3. Turn the tee handles on the 1S-8938 Chucks counterclockwise in order to ensure that the charging
valves will not open during installation.
Note: When the suspension cylinders have bottomed completely, leave the 1S-8938 Chucks in
position for five minutes in order to allow the pressure in the suspension cylinders to equalize.
The collapsed rod length is 17.2 mm (0.67 inch).
Typical example
(3) Reference line
(5) Reference line
the axle (4) .
Typical example
One FT1680 Gauge Block (6) is required for each suspension cylinder. These gauge blocks are required
for correct service of the front suspension cylinders.
Example
10°C (50°F) − (−40°C (−40°F)) = 50°C (90°F)
Shim thickness:
50°C (90°F) × 3.2 mm (0.125 inch) ÷ 5.5°C (10°F) = 29.1 mm (1.125 inch)
170.0 mm (6.69 inch) + 29.1 mm (1.125 inch) = 199.1 mm (7.81 inch)

Table 31
Tools Needed

movement.


released.

1. Ensure that the cylinders have been purged of nitrogen and oil.
Note: The collapsed rod length is 17.2 mm (0.67 inch).
The pressure tap is located on the steering disable valve.
2. Construct an appropriate charging hose from the 8T-5320 Hydraulic Test Group .
3. Connect the charging hose to 1S-8938 Chuck .
4. Connect charging hose to the pressure tap on the steering disable valve. The steering disable valve
is located on the frame in front of the fuel tank on the left side of the machine. Refer to Illustration
40 in order to view the location of the steering disable valve.
5. Connect 1S-8938 Chucks to charging valves (2) .
7. Turn the tee handle on the 1S-8938 Chuck clockwise. This opens up charging valve (2) .
Note: If necessary, bleed the air from the oil by opening the second charging valve (2) and add oil
until oil flows through the second charging valve (2) without air in order to ensure proper
performance of the cylinder.
8. Turn the swivel nut counterclockwise. This opens the charging valves (2) .
9. Inject oil into the suspension cylinder until the correct reference dimension is reached. Refer to the
""Setting Up For Measurement" " section in this document in order to view the reference
dimension.
10. Turn the tee handles on the 1S-8938 Chuck counterclockwise. This closes the charging valves
(2) .
11. Turn the swivel nut clockwise. This closes the charging valves (2) .
Note: After the charge pressure has returned to zero, use the quick couplers to remove the
charging hoses.

Refill Pump
Table 32
Tools Needed

movement.


released.

Correct oil level
(3) Reference line
(125 psi).
on the cylinder.
5. Close the swivel valve. Turn swivel nut (A) clockwise. This closes the valve.

Table 33
Tools Needed

FT-1680 Gauge Blocks 2

NOTICE
2. Adjust the nitrogen in order to provide 2415 kPa (350 psi) for the 770. Adjust the nitrogen in
order to provide 2760 kPa (400 psi) for the 772.
3. Open the shutoff valves in order to allow nitrogen to flow to 1S-8938 Chuck .
4. Turn the tee handles on the 1S-8938 Chuck clockwise. This opens up charging valves (2). This
5. Open the swivel valve. Turn swivel nut (A) counterclockwise in order to open the valve.
6. Allow nitrogen into the suspension cylinder until the gauge block (6) and any required shims can
be inserted between the axle and the suspension cylinder. Refer to Illustration 39 in order to view
gauge block (6) .
7. Lower the nitrogen pressure until the housing for the strut is setting on gauge block (6) .
8. Turn the swivel nut clockwise on the charging valves. This closes the charging valves.
9. Close both shutoff valves. Turn the tee handles on the 1S-8938 Chuck counterclockwise.
10. Remove the 7S-5437 Nitrogen Charging Group . Install the valve caps (1) to the charging valves
(2) .
11. Torque the valve caps (1) between 2 N·m (18 lb in) to 3 N·m (27 lb in).
12. Start the engine.
13. In order to remove the gauge blocks (6), raise the truck body and turn the steering wheel so that
the front wheels move. The suspension should raise.
14. Remove gauge blocks (6) when the suspension cylinders are not resting on gauge blocks (6) .
15. Operate the machine through a load and a dump cycle. Verify that the correct exposed rod
dimension is achieved. The correct amount of exposed rod is 170 mm (6.7 inch) plus any required
shims.
Note: Record this measurement. Use these recorded measurements as a reference when you
inspect the front suspension cylinders for the correct ride height.
Worksheets
Table 34

Component Damage
Table 35

Left Right
Oil Leaks
Nitrogen Leaks
Table 36
Outside Temperature
770 and 772 Rear Suspension Cylinder (Purge and Charge)

must be empty. Coast the machine to a gentle stop without using the brakes. Take note of the current
ride height of the suspension cylinders. Look up the dimensions for the previous ride height of the
suspension cylinders after the last nitrogen charging procedure. Compare the two values. The suspension
height will be different for each machine.
Table 37
Tools Needed
1S-8938 Chucks 2
Note: When you work with the 238-9928 Valve As , two 1S-8938 Chucks will be needed.

movement.


released.

(1) Valve cap
(2) Charging valve
2. Before you install the 1S-8938 Chucks to charging valve (2), turn the tee handles
counterclockwise in order to ensure that the charging valves (2) will not open during installation.
3. Install the charging hoses to charging valves (2) with 1S-8938 Chucks . The charging hoses will
be used to drain oil into an approved container.
NOTICE
containing fluids.

(1) Valve cap
(2) charging valve
(A) Swivel nut
4. Turn swivel nut (A) counterclockwise on charging valve (2). This opens the charging valve (2) .
Note: The valve core is to aid in charging. The valve core is intended as a safety backup for
charging valve (2). The valve core is not intended as a primary seal. The swivel nut must be in the
closed position prior to installing the charging equipment.
5. Turn the tee handle on the 1S-8938 Chucks clockwise in order to allow nitrogen to flow through
charging valves (2). When the suspension cylinders have bottomed completely, leave the chucks
in position for five minutes in order to allow the pressure in the suspension cylinders to equalize.
Determining the Correct Pin to Pin Dimension
1. Verify the collapsed pin to pin dimension of 681 mm (26.8 inch).
2. Measure the difference between the outside ambient temperature and the temperature of the
service shop. If the temperature difference is less than (20° F), no action needs to be taken.
Proceed to the ""Oil Charging Procedure" " section in the manual if the temperature is acceptable.
If the temperature is not acceptable proceed to Step 3.
3. If this temperature difference is greater than (20° F), you will need to adjust the final pin to pin
dimension of 780 mm (30.7 inch). Add 2.54 mm (0.100 inch) to the pin to pin dimension for each
(10° F) of temperature difference.
Note: Estimate the temperature difference to the nearest (10° F).
Example
Temperature of the service shop ... 50° F
Outside ambient temperature ... -40° F
Difference in temperature ... (50° F) - (-40° F) = 90° F
Additional length for the temperature compensation ... (90° F * .10 in) / 10° F = .90 in
Corrected guidelines for the nitrogen charging procedure ... 780 mm + 23.1 mm (.90 in) =
803.1 mm (31.60 in)
Table 38
Tools Needed
1S-8938 Chucks 2

movement.


released.

1. Ensure that the cylinders have been purged of nitrogen and oil. The collapsed pin to pin dimension
is 681 mm (26.8 inch).
2. Assemble an appropriate charging hose from the 8T-5320 Hydraulic Test Group .
3. Connect the appropriate charging hose to the 1S-8938 Chuck .
View of rear brake slack adjuster
4. Connect the charging hose to the pressure tap on the rear brake slack adjuster. The slack adjuster
is located in front of the rear axle housing.
5. Connect 1S-8938 Chuck to charging valves (2). Refer to Illustration 43 in order to view the
location of charging valve (2) .
6. Start the machine and apply the manual retarder.
7. Turn the tee handle on the 1S-8938 Chuck clockwise. This opens up charging valve (2) .
Note: If necessary, Open the second charging valve (2) and add oil until oil flows through the
second charging valve (2) without air.
8. Turn swivel nut (A) counterclockwise on charging valve (2). This opens the charging valve (2) .
9. Inject oil into the suspension cylinder until the correct pin to pin dimension is reached.
Note: The correct pin to pin dimension is 780 mm (30.7 inch) prior to any required adjustments
due to temperature.
10. Turn the tee handles on 1S-8938 Chuck counterclockwise. This closes charging valves (2) .
11. Turn swivel nut (A) clockwise on charging valve (2). This closes the charging valve (2) .
12. Disengage the manual retarder. Shut down the machine.
hoses.

Refill Pump
Table 39
Tools Needed

movement.


released.

Correct oil level
(3) Reference line
(125 psi).
on the cylinder.
5. Close the shutoff valves. Turn swivel nut (A) clockwise. This closes charging valves (2) .

Table 40
Tools Needed
1S-8938 Chucks 2

movement.


released.

Typical example of the setup for the nitrogen charging procedure
the charging valves (2) on each suspension cylinder.
Note: In order to prevent oil flow into the charging hoses, do not open the charging valves (2) at
this time.
3. Open the shutoff valves in order to allow nitrogen to flow to the 1S-8938 Chuck .
4. Turn the tee handles on the 1S-8938 Chuck clockwise in order to open charging valves 2. This
5. Allow nitrogen into the suspension cylinder until the correct pin to pin dimension is achieved.
Note: The correct pin to pin dimension is 780 mm (30.7 inch). The fully extended dimension is
830.6 mm (32.7 inch).
other suspension cylinder until the correct extension has been achieved.
valves.
7. Turn the swivel nut clockwise on charge valve (2). This will close charge valve (2) .
8. Turn the tee handles on 1S-8938 Chuck counterclockwise.
9. Turn off the nitrogen pressure at the supply tank.
10. Remove 175-5507 Nitrogen Charging Group and the 175-7410 Nitrogen Charging Fitting Gp .
11. Install valve caps (1) on charging valves (2) .
12. Torque valve caps (1) between 2 N·m (18 lb in) and 3 N·m (27 lb in).
Record this value. Use this record as a reference when the rear suspension cylinders are inspected.
14. Operate the machine through a cycle and check the ride height. If the ride height has changed,
adjust the nitrogen pressure until the correct ride height is reached. Record the final ride height
and pressure.
Worksheets
Table 41

Component Damage
Table 42

Left Right
Oil Leaks
Nitrogen Leaks
Table 43
Outside Temperature
Copyright 1993 - 2011 Caterpillar Inc. Thu Aug 11 16:56:13 UTC-0400 2011
Todos los derechos reservados.
Red privada para licenciados del SIS.

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773F OEM Off-Highway Truck EXD00001-UP (MACHINE) POWERED BY C27 Engin...

Servicing the Suspension Cylinders for Off-Highway Trucks

Personal injury or death can result from sudden suspension cylinder

Sudden movement, up or down, can cause the clearance above your

Read all warning labels on the suspension cylinders before servicing. Do

Do not stand under the machine when testing or adjusting the

Personal injury or death can result from improper lifting or blocking.

Approximate weights of the components are shown. Clean all surfaces

Important Safety Information

The signal word "WARNING" has the following meanings:

 Your Safety Is Involved !

Improper operation, lubrication, maintenance or repair of this product

Do not operate or perform any lubrication, maintenance or repair on

Always observe the list of basic precautions that follows:

Mounting and Dismounting

Specifications for Cables, Chains, and Lifting Devices

Hot Fluids and Parts

Ensure that the fuel tank is full of fuel.

Servicing Suspension Cylinders

Conditions for Servicing

 Suspension cylinder shows signs of leakage.

available. Refer to ""Machine Preparation" ".

777 Front Suspension Cylinder (Purge and Charge)

Purge the Suspension Cylinder of Oil and of Nitrogen

Personal injury or death can result from sudden suspension cylinder

Sudden movement, up or down, can cause the clearance above your

Read all warning labels on the suspension cylinders before servicing. Do

Do not stand under the machine when testing or adjusting the

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Dispose of all fluids according to local regulations and mandates.

(1) Valve cap

(2) Charging valve

(2) Charging valve

(A) Swivel nut

Setting Up For Measurement

(4) Top edge of the axle

(5) Reference line

Note: Estimate the temperature difference to the nearest 5.5°C (10°F).

Temperature of the service shop ... 10°C (50°F)

Outside ambient temperature ... −40°C (−40°F)

10°C (50°F) − (−40°C (−40°F)) = 50°C (90°F)

Dimension for the nitrogen charging procedure

170.0 mm (6.69 in) + 46.4 mm (1.80 in) = 216.4 mm (8.48 in)

Oil Charging Procedure

Personal injury or death can result from sudden suspension cylinder

Sudden movement, up or down, can cause the clearance above your

Read all warning labels on the suspension cylinders before servicing. Do

Do not stand under the machine when testing or adjusting the

Note: The collapsed rod length is 3 mm (0.120 inch).

1. Connect the charging hose to the 1S-8938 Chucks .

3. Connect 1S-8938 Chucks to charging valves (2) .

4. Start the machine.

5. Apply the manual retarder.

10. Disengage the manual retarder.

11. Shut down the machine.

Oil Charging Procedure That Uses The Optional 9U-5617 Oil

Personal injury or death can result from sudden suspension cylinder

Sudden movement, up or down, can cause the clearance above your