Carga Suspensiones 789D

29/8/2017 Bsqueda del medio - SEHS9411 - Servicing the Suspension Cylinders for Large Off-Highway Trucks {0756, 7200,
0756, 7200, 7201, 7201, 7201, 7213}
Pantalla anterior
Bienvenido: r120hxrc
Producto: NO SE HA ESCOGIDO NINGUN EQUIPO
Modelo: NO SE HA ESCOGIDO NINGUN EQUIPO
Conguracin: NO SE HA ESCOGIDO NINGUN EQUIPO
Instruccin Especial
Servicing the Suspension Cylinders for Large Off-Highway Trucks {0756, 7200, 7201, 7201, 7201, 7213}
Nmero de medio -SEHS9411-25 Fecha de publicacin -30/04/2015 Fecha de actualizacin -28/08/2017

i07155962
Servicing the Suspension Cylinders for Large Off-Highway Trucks

{0756, 7200, 7201, 7201, 7201, 7213}
SMCS - 0756; 7200; 7201-542; 7201-735; 7201-745; 7213
OEM
CAT WDS (S/N: M4J1-UP)
Off-Highway Truck/Tractor
784B (S/N: 5RK1-UP)
784C (S/N: 2PZ1-UP)
785 (S/N: 8GB1-UP)
785B (S/N: 6HK1-UP)
785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP)
785D (S/N: DMC1-UP; MSY1-UP)
789 (S/N: 9ZC1-UP)
789B (S/N: 7EK1-UP)
789C (S/N: 2BW1-UP)
789D (S/N: SPD1-UP; SHH1-UP; TWP1-UP)
793 (S/N: 3SJ1-UP)
793B (S/N: 1HL1-UP)
793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP)
793D (S/N: FDB1-UP)
793F (S/N: SND1-UP; SSP1-UP; SXP1-UP; RBT1-UP)
793F AC (S/N: EMD1-UP)
795F AC (S/N: ERM1-UP)
795FAC XQ (S/N: SNT1-UP)
797 (S/N: 5YW1-UP)
797B (S/N: JSM1-UP)
797F (S/N: LAJ1-UP; WSP1-UP)
Reference: Special Instruction, REHS9345, "Procedure to Troubleshoot the Loss of Nitrogen Precharge or Oil
from Suspension Cylinders"
Introduction
This Special Instruction contains the preparation information and procedure required for purging the oil and
nitrogen from the suspension cylinders on Large Off-Highway Trucks. Also, this document contains an
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29/8/2017 Bsqueda del medio - SEHS9411 - Servicing the Suspension Cylinders for Large Off-Highway Trucks {0756, 7200, 7201, 7201, 7201, 7213}
incremental charging procedure for the oil and nitrogen used in the suspension cylinders on Large Off-Highway
Trucks.
Read the entire document before you proceed with any work on the suspension cylinders. Trucks may have
different weight congurations due to differences in dump body, liners, engines, custom attachments. The different
weight congurations can cause varied carry pressures.
The suspension system on Large Off-Highway Trucks consists of four suspension cylinders. The benets of
charging the suspension cylinders with the proper amount of oil and nitrogen include:
Better machine ride
Improved structural durability
Improved shock absorption and operator comfort
Higher suspension cylinder reliability
Improved ability to maintain the intended level of controllability
Better operating efciency
Increased accuracy of the payload measurement system
NOTICE
Failure to follow the procedures to charge the suspension cylinders
properly can lead to damage to the frame.
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 and 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 identies 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 identied 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. Obtain
knowledge of the system and knowledge of the component before removing any component or disassemble any
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. A
determination must be made by you that the operation, lubrication, maintenance, and repair procedures
will not make the machine unsafe.
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

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.

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.
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.
Read all Warning labels on the suspension cylinders before servicing.
The vehicle must be on level ground before releasing the nitrogen

pressure.
Do not check the oil in the suspension cylinder until all of the nitrogen
pressure has been released.
Do not remove valves, covers or plugs from the cylinder unless the rod is
fully retracted and all of the nitrogen pressure has been released.
Do not stand under the machine during suspension cylinder charging,

discharging, or testing and adjusting procedures or while lifting or
lowering the machine. Sudden movement upward or downward can
cause the clearance above your head to change rapidly.
Failure to heed this Warning could lead to injury or death.
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 identication 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).
When applying an oil charge or a nitrogen charge with the machine on

the ground, the machine may suddenly move due to internal sticking of
the suspension cylinders.
High Pressure Cylinder. Do not remove any grease tting, valve or plug
until the truck is supported and pressure is relieved or the truck may
drop suddenly, resulting in personal injury.
Suspension groups should only be serviced by properly trained

personnel who have read and understand the service manual procedure
to relieve pressure and to charge cylinders.
NOTICE
Care must be taken to ensure that uids are contained during
performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the uid with suitable containers
before opening any compartment or disassembling any component
containing uids.
Refer to Special Publication, NENG2500, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain uids on
Cat products.
Dispose of all uids according to local regulations and mandates.
NOTICE
Failure to charge the suspension cylinders properly can lead to damage
to the frame.
Always observe the list of basic precautions that follows:
Safety Signs
Safety information is presented by the following: 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 charge the suspension cylinders. 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 2 feet and 1 hand. Three-point contact can also be 1 foot and 2 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.
Specications for Cables, Chains, and Lifting Devices
Use approved cables, chains, and lifting devices to lift components. Refer to the manufacturer's weight
specications 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 3 to view the effect of the lift angle on
the working load limit.
Note: The lifting devices illustrated 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 been stopped and hot uids in lines, tubes and
compartments.
Be careful when you remove ller caps, breathers, and plugs on the machine. Hold a rag over the cap or plug to
prevent being sprayed by pressurized liquids. When the machine has been stopped, the danger of hot uids 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. If there is
contact, immediately wash skin with soap and water. For contact with the eyes, ush 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 uid under pressure can
penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can
cause severe injury. If uid 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, ttings, 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 res. Lubrication lines that are damaged
and lubrication lines that are loose can cause res. Hydraulic lines, tubes, and hoses that are damaged can
cause res. Hydraulic lines, tubes, and hoses that are loose cause res. 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 uids 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 high. The nozzle pressures are frequently above 13790 kPa (2000 psi). Follow all the
recommended practices that are provided by the manufacturer of the pressure washer.
Denitions
Carry or On the Ground Pressure - The Carry Pressure is the pressure seen in the suspension cylinders when the
truck has come to a rolling gradual stop on level ground
Pre-Charge or Extended Charge Pressure - The Pre-Charge Pressure, or Extended Charge Pressure, is the
pressure in the suspension cylinders when the machine is raised off the ground and the cylinders are extended
completely.
Ride Height - The Ride Height is used as a target value for charging the suspension cylinders. The Ride Height for
each suspension cylinder is the cylinder length, and is dened by the measurement of the exposed surface area of
the cylinder rod. For the front cylinders, the Ride Height is the distance from the bottom of the cylinder housing to
the top of the wheel spindle or hub. For the rear cylinders, the Ride Height is the distance from the bottom of the
cylinder housing to the chamfer edge on the rod where the nished surface begins. Note: If the machine is
equipped with a stop collar on the wheel group, measure the exposed surface from the bottom of the
suspension housing to the top of the stop collar. If, the machine is not equipped with a stop collar then
measure the exposed surface from the bottom of the suspension housing to the top of the wheel spindle or
hub.
Rolling Stop - Position the machine on level ground. Bring the machine to a smooth gradual stop. A sudden stop
will alter the amount of exposed surface area. A sudden stop will also invalidate the information that is used to
determine if the machine needs to be serviced.
Caterpillar Channel 1 Video
Reference: For additional information, refer to CATU1669, "Servicing and Maintaining the Suspension Cylinders
for Large Off-Highway Trucks - SEHS9411" on CaterpillarChannel 1.
https://channel1.videonitch.com/LearningPrograms/Pass/7181
Note: A CWS login is required to access CaterpillarChannel 1.
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 collapsed.
Suspension cylinder shows signs of leakage.
The travel of the suspension cylinder rod is limited.
The weight of the truck changes more than 2268 kg (5000 lb).
The suspension cylinder pressures vary 345 kPa (50 psi) (Front) or 1035 kPa (150 psi) (Rear) more in
comparison to the other side when the truck is empty. 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 the recommended tolerance for that machine.
Refer to the Operation and Maintenance Manual, "Maintenance Interval Schedule" to check the suspension
cylinders at the correct intervals.
Note: In the analysis of a problem in the suspension cylinders, each cylinder operates as a separate unit. However,
the condition of charge in one cylinder can impact the ride height of the other three cylinders. For example, 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.
Note: Cylinders are always serviced in pairs. If one cylinder exhibits any of the aforementioned conditions, the
opposite side should be serviced along with the cylinder with the issue. For example, if the left rear suspension
cylinder exhibits an issue, the left rear and the right rear suspension cylinders should be serviced as a pair.
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.
Ensure that the fuel tank is full of fuel.
Drive the machine for at least 20 minutes to warmup the suspension cylinders. Bring the machine to a smooth
gradual stop on level ground before measuring the ride height or servicing the suspension cylinders.
Note: If the service that is going to be performed is a collapse and recharge, it is not required to drive the machine
for 20 minutes and bring to a smooth gradual stop.
Make sure that the truck is turned off. Make sure that the wheel chocks are in place after the machine is parked.
Make sure that the battery disconnect switch is turned OFF.
Match the correct lift stand with the weight of the truck that is being serviced.
Visual Inspection
Perform a visual inspection on the suspension cylinder before you work on the suspension cylinder. 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. A nitrogen leak is difcult to detect. A solution that consists
of soap and of water can be used to detect leaks.
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 all or some of the head bolts to prevent removal of the head while there is pressure in the suspension
cylinder.
Do not adjust, loosen, or remove the protective plates to inspect for leaks
as it will release the pressure in the strut resulting in the truck to drop
suddenly that could result in personal injury or death.
Note: Use a ladder or appropriate device to reach the appropriate height to inspect the charging valves.
Note: 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. Eventually, the wear band
should become soaked by oil and grease and the blackening should decrease.
Typical view of limited suspension travel
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Illustration 4 is an example of limited suspension travel. If limited suspension travel is observed, both front
suspension cylinders should be collapsed and recharged.
Typical view of grease not present at the relief valve and grease build-up on the rod surface
Illustration 5 is an example of grease not present at the relief valve and grease build-up on the rod surface. If
grease is not present at the relief valve and grease build-up on the rod surface is observed, the grease valves should
be replaced and the automatic lubrication system should be checked for proper functionality.
Oil Requirements
Table 1
Required Oil
Cat TDTO SAE 10W
Table 2
Friction Modier Mixing Instructions (99% Suspension Oil, 1%
Friction Modier
Friction Modier)
Part Number Suspension Oil Friction Modier
3.78 L (1 US gal) 37.89 mL (1.28 oz)

1U-9891 Hydraulic Oil Additive
(1 qt container of 100% Friction 18.9 L (5 US gal) 189.4 mL (6.4 oz)
Modier)
208 L (55 US gal) 2083.8 mL (70.4 oz)
Note: Friction modier must be mixed with the suspension oil before the suspension cylinders are charged with
oil.
Required Tools
Table 3
Tool Chart
Item Part Number Description Qty
A 9U-5617 Or FT-3315 Oil Rell Pump(1) Or Tool Group Nitrogen Fill- Alternative(2) 1
B 175-5507 Nitrogen Charging Group(1) 1
C 175-7410 Nitrogen Charging Fitting Gp(1) 1
D Lift Stands(3) 2
(1) When you work with the 238-9928 Valve As as a charging valve, two 1S-8938 Chucks will be needed instead of the two 7S-5106
Chucks.
(2) The additional part number is an FT drawing Should a dealer want to fabricate, the dealer can use the FT-3315 Tool Group Nitrogen Fill-
Alternate in place of the 9U-5617 Oil Rell Pump.
(3) Match the correct lift stand (D) with the weight of the truck that is being serviced.
Reference: Special Instruction, NEHS0742 for assembly instructions for tool (B) and tool (C).
Tool 9U-5617 Oil Rell Pump (A)
( 1) Shutoff valve for the regulator
(2) 7S-5106 Chuck or 1S-8938 Chuck
(3) Shutoff valve
(4) Charging hoses
Tool 175-5507 Nitrogen Charging Group (B)
( 2) 7S-5106 Chuck or 1S-8938 Chuck
(5) 162-4147 Hose As
(6) 8S-4600 Fitting
(7) 8S-1506 Coupling
(8) 162-4146 Regulator
(9) 8T-0859 Pressure Gauge
(11) 2S-5244 Fitting
(12) 1S-8937 Needle Valve
(13) 2D-7325 Pipe Tee
(14) 1S-8941 Hose As
Tool 175-7410 Nitrogen Charging Fitting Gp (C)
( 2) 7S-5106 Chuck or 1S-8938 Chuck
(16) 1S-8941 Hose As
(17) 175-6857 Hose As
(18) 2D-7325 Pipe Tee
(19) 1S-8937 Needle Valve
(20) 5P-8998 Fitting
(21) 3D-8884 Elbow
175-7410 Nitrogen Charging Fitting Gp (C) is used with 175-5507 Nitrogen Charging Group (B) to charge the
suspension cylinders. 8T-0859 Pressure Gauge (9) is used to check the pressure of the cylinder before the charging
procedure is performed.
Procedure for the Rear Suspension Cylinders

Collapse the Rear Suspension Cylinders
NOTICE
To ensure that the seals on the suspension cylinders do not get
damaged, ensure that the exposed chrome is clean and free from any
damage or debris prior to collapsing the suspension cylinders.
Note: Both rear suspension cylinders must be collapsed at the same time. If only one suspension cylinder needs
servicing, perform the procedure on both suspension cylinders.
Note: The cylinders must be collapsed before the charge procedure is executed. The actual amount of oil in a
cylinder cannot be determined at a given time after the machine has been in service. The suspension cylinder must
be collapsed and lled with a known amount of oil.
Illustrative view of collapsing rear suspension cylinders
(AA) Charging valve
Typical view
(AA) Charging valve
(AB) Valve cap
1. Remove and retain one valve cap (AB) from a charging valve (AA) on each of the rear suspension cylinders.
Note: These valves will be the outlet valves.
Typical view
2. Locate two chucks (2) that are part of the nitrogen charging group.
Install the charging hoses to chuck (2).
Note: The charging hoses will be used to drain oil into an approved container.
Turn the tee handle counterclockwise on chucks (2) to ensure that the valve cores on the charging valves will
not open during installation.
Typical view
(AA) Charging valve
3. Install one chuck (2) onto a charging valve (AA) on each of the rear suspension cylinders.
Note: These lines will be the oil outlet drain lines.
Note: Ensure that the charging hose can drain into a suitable container.
4. Turn the nut that is on outlet charging valve (AA) counterclockwise to open charging valves (AA).
Turn the tee handle that is on chucks (2) clockwise to depress the core valve on charging valves (AA).
Open any needle valves that are installed on the charging hoses.
Note: Opening the outlet charging valves (AA) and chucks (2) allows oil and nitrogen to ow through the
charging valves so that the suspension cylinders will collapse completely.
5. Let oil and nitrogen ow into the suitable container until the suspension cylinders have collapsed
completely.
Note: Due to the stiffness of the frame and body, both rear suspension cylinders may not fully collapse. If
the suspension cylinders do not fully collapse, it may be required to place two jacks on the jacking pads
located under the rear axle housing .Then extend the jacks until both rear cylinders are collapsed completely
.
6. After the suspension cylinders have collapsed completely, leave the charging valves in the open position for
approximately 15 minutes. Allow the pressure in the suspension cylinders to equalize with atmosphere.
Refer to Table 4 for the approximate collapsed exposed chrome height.
7. Mark the location of the collapsed suspension cylinders.
8. If the suspension cylinders were recently purged with oil, close any needle valves that are installed on the
charging hoses. Then turn the tee that is on chucks (2) counterclockwise to close the core valve on outlet
charging valves (AA) and turn the nut that is on outlet charging valves (AA) clockwise to close the charging
valves. Remove chucks (2) from charging valves (AA). Proceed to Section "Charge the Rear Suspension
Cylinders with Oil".
If annual maintenance is being performed, proceed to Section "Purge the Rear Suspension Cylinders with
Oil".
Purge the Rear Suspension Cylinders with Oil
Illustrative view of purging the rear suspension cylinders with oil
(A) 9U-5617 Oil Rell Pump
(AA) Charging valve
Typical view
(AA) Charging valve
(AB) Valve cap
(AA) Charging valve - Installation torque 13.6 0.5 Nm (120.37 4.42 lb in)
(AB) Valve cap - Installation torque 2.5 0.5 Nm (22.12 4.42 lb in)
(AC) Valve core - Installation torque 0.5 0.1 Nm (4.42 0.88 lb in)
(AD) Swivel nut - Closure torque 6.8 0.5 Nm (60.18 4.42 lb in)
1. Remove and retain the remaining valve caps (AB) from both charging valves (AA) on each of the rear
suspension cylinders.
Note: These valves will be the inlet valves.
2. Ensure that swivel nuts (AD) are turned clockwise completely to close charging valves (AA).
Typical view
Install the charging hoses to the chucks (2).
Note: Two of the charging hoses, oil outlet drain lines that were installed in Section "Collapse the Rear
Suspension Cylinders", will be used to drain oil and nitrogen into an approved container. The two charging
hoses that will be installed in this section are used to pump oil into the suspension cylinders.
Turn the tee handle that is on chucks (2) counterclockwise to ensure that the charging valves will not open
during installation.
(AA) Charging valve
4. Secure a chuck (2) to each charging valve (AA) on both rear suspension cylinders.
Note: These lines will be the oil inlet lines.
5. Connect the charging hoses and the rest of tooling (A) to chucks (2) on the inlet charging valves.
6. Open shutoff valves (3) on Tool (A). Adjust the pressure on the regulator.
Reference: Refer to Illustration 7 to view shutoff valve (3).
7. Turn the two swivel nuts (AD) counterclockwise to open the inlet charging valves (AA).
8. Turn the tee handle on the two inlet valves chucks (2) clockwise to open valve cores (AC).
9. Begin to operate Tool (A) and pump oil into both rear suspension cylinders and out the drain hoses.
Continue to pump oil into the rear suspension cylinders until the oil that comes from the drain hose on the
outlet charging valves are mostly free of bubbles.
10. After the discharged oil is mostly free of bubbles, stop the pump and turn the tee That is on chucks (2)
counter-clockwise to close the core valve on outlet charging valves (AA). Turn the nut that is on outlet
charging valves (AA) clockwise to close the charging valves to stop any ow draining from the cylinders.
Remove two chucks (2) that were connected to the outlet charging valves.
Note: If performing the annual maintenance on the system, refer to Section "Preventive Maintenance for the
Sensor, the Charging Valve, and the Manifold", and the Operation and Maintenance Manual for the machine
being serviced.
11. Proceed to Section "Charge the Rear Suspension Cylinders with Oil".
Charge the Rear Suspension Cylinders with Oil
Illustrative view of charging the rear suspension cylinders with oil
(AA) Charging valve
(BB) Exposed surface area measurement
NOTICE
If the technician is not performing the yearly maintenance and purging
the suspension cylinders now, the technician will need to install the oil
pump and inlet charge lines. Follow Steps 1 through 7 in Section
"Purge the Rear Suspension Cylinders with Oil" before beginning the
next section "Charge the Rear Suspension Cylinders with Oil"
1. Start tool (A) and pump oil into each suspension cylinder to increase the cylinder height by 25.4 mm
(1.0 inch).
Note: If one suspension cylinder reaches 25.4 mm (1.0 inch) of oil before the other suspension cylinder,
close shutoff valve (3) for that suspension cylinder. Continue injecting oil into the other suspension cylinder
until 25.4 mm (1.0 inch) is achieved.
2. Close all valves on tooling (A), turn the tee that is on chucks (2) counter-clockwise to close core valve on
inlet charging valves (AA) and turn the nut that is on inlet charging valves (AA) clockwise to close the
charging valves.
3. Remove two chucks (2) that were connected to the inlet charging valves.
4. Proceed to Section "Charge the Rear Suspension Cylinders with Nitrogen"
Charge the Rear Suspension Cylinders with Nitrogen
Illustrative view of charging the rear suspension cylinders with nitrogen
(AA) Charging valve
Typical view
(AA) Charging valve
1. Ensure that no oil is left in the hoses. If required, purge the charge hoses of oil.
Install one chuck (2) onto a charging valve (AA) on each of the rear suspension cylinders. These valves will
be the nitrogen charging valves.
2. Attach Tool (B) and the charging hoses to chucks (2).
3. Turn swivel nut (AD) counterclockwise to open the charging valve to valve core (AC).
4. Turn the tee handle that is on chucks (2) clockwise to open valve cores (AC) on the charging valve on each
suspension cylinder.
5. To prevent a vacuum when the truck is raised later in the charging process, add approximately 1000 kPa
(150 psi) of nitrogen to the rear suspension cylinders.
Note: Ensure that the valve for the nitrogen remains open and regulated to 1034 kPa (150 psi) while lifting
the truck to prevent a vacuum.
Typical example of Lift Stands (D) that are lifting a machine
6. Place a suitable lifting device under the hoist tube.
Note: Refer to the lifting instructions in the "Specications for Cables, Chains, and Lifting Devices" Section
within this special instruction.
7. Lift the truck until both of the rear suspension cylinders are fully extended and the tires off are the ground.
Allow nitrogen to enter the suspension cylinders until the target extended charge pressure is reached.
Note: The rear extended pressures are required to be equal. Refer to the target pressures that are specic to
your machine, at your site, and must be developed by you. Refer to Table 4 for a reference to the extended
charge pressures. The pressures in Table 4 are a recommended starting point.
8. After the charge is complete, close the valve on tooling (B) to stop the ow of nitrogen and allow the
pressure to equalize between suspension cylinders. Close the remaining valves on tooling (B), Tees on
chucks (2) and the swivel nuts (AD) on the charging valves.
9. Remove tool (B) from the charging valves. Install all the valve caps to the charging valves. Check for any
leaks.
10. Tighten the valve caps to a torque of 2.5 to 3.5 Nm (22 to 31 lb in).
11. Lower the truck from the stands.
12. After both the front and rear suspension cylinders are charged, drive the machine for at least 10 minutes on a
route that includes both left and right turns. Bring the machine to a gradual stop on level ground.
Note: A sudden stop will alter the amount of exposed surface area. A sudden stop will also invalidate the
information that is used to determine if the machine needs to be serviced.
13. Measure the exposed surface area and compare to the ride height listed in Table 4. If the measured exposed
surface area is out of tolerance, repeat Step 1 through Step 13 of this Section to add or remove nitrogen as
appropriate to achieve the desired ride height.
Note: Adjust the extended charge pressure in each cylinder by increments of +/- 138 kPa (20 psi) until the
desired ride height is achieved.
After achieving the desired ride height from Table 4, record the extended suspension cylinder charge
pressures.
Note: The site recorded pressures and ride heights can be used for all trucks with the same approximate
weight and the same machine conguration.
14. Use the recorded dimensions and the extended charge pressure as a reference in this Special Instruction,
"Conditions for Servicing". Use the recorded dimensions as a reference when you inspect the rear
suspension cylinders according to the Operation and Maintenance Manual, "Maintenance Interval
Schedule".
Procedure for the Front Suspension Cylinders

Collapse the Front Suspension Cylinders
NOTICE
To ensure that the seals on the suspension cylinders do not get
damaged, ensure that the exposed chrome is clean and free from any
damage or debris prior to collapsing the suspension cylinders.
Note: The cylinders must be collapsed before the charge procedure is executed. The actual amount of oil in a
cylinder cannot be determined at a given time after the machine has been in service. The suspension cylinder must
be collapsed and lled with a known amount of oil.
Note: It is recommended that both front suspension cylinders be serviced at the same time. If only one suspension
cylinder needs servicing, perform the procedure on both suspension cylinders.
Note: Any time the suspension is apart ll cavity with grease again. The OMM manual has a section stating that
every year the cylinders should be purged of the oil and nitrogen charge and recharged. Replace the grease relief
valve ttings and this time would be the optimal to ush the grease that is in the cylinder out and put new grease in
the cylinder.
Illustrative view of collapsing a front suspension cylinder
(AA) Charging valve
Typical view
(AA) Charging valve
(AB) Valve cap
1. Remove and retain one valve cap (AB) from a charging valve (AA) on each of the front suspension
cylinders.
Note: These valves will be the outlet valves.
Typical view
Install the charging hoses to chuck (2)
Note: The charging hoses will be used to drain oil into an approved container.
Turn the tee handle counterclockwise on chucks (2) to ensure that the valve cores on the charging valves will
not open during installation.
Typical view
(AA) Charging valve
3. Install one chuck (2) onto a charging valve (AA) on each of the front suspension cylinders.
Note: These lines will be the oil outlet drain lines.
Note: Ensure that the charging hoses can drain into a suitable container.
4. Turn the nut that is on outlet charging valves (AA) counterclockwise to open charging valves (AA).
Turn the tee handle that is on chucks (2) clockwise to depress the core valve on charging valves (AA).
Open any needle valves that are installed on the charging hoses.
Note: Opening the outlet charging valves (AA) and chucks (2) allows oil and nitrogen to ow through the
charging valves so that the suspension cylinders will collapse completely.
5. Let oil and nitrogen ow into the suitable container until the suspension cylinders have collapsed
completely.
6. After the suspension cylinders have collapsed completely, leave the charging valves in the open position for
approximately 15 minutes to allow the pressure in the suspension cylinders to equalize with the atmosphere.
Refer to Table 5 for the approximate collapsed exposed chrome height.
7. Mark the location of the collapsed suspension cylinders.
8. If the suspension cylinders were recently purged with oil, close any needle valves that are installed on the
charging hoses. Then turn the tee that is on chucks (2) counter-clockwise to close the core valve on outlet
charging valves (AA) and turn the nut that is on outlet charging valves (AA) clockwise to close the charging
valves. Remove two chucks (2) from charging valves (AA). Proceed to Section Charge the Front
Suspension Cylinders with Oil. If the annual maintenance is being performed, proceed to section Purge the
Front Suspension Cylinders with Oil.
Purge the Front Suspension Cylinders with Oil
Illustrative view of purging a front suspension cylinder with oil
(AA) Charging valve
Typical view
(AA) Charging valve
(AB) Valve cap
(AA) Charging valve - Installation torque 13.6 0.5 Nm (120.37 4.42 lb in)
(AB) Valve cap - Installation torque 2.5 0.5 Nm (22.12 4.42 lb in)
(AC) Valve core - Installation torque 0.5 0.1 Nm (4.42 0.88 lb in)
(AD) Swivel nut - Closure torque 6.8 0.5 Nm (60.18 4.42 lb in)
1. Remove and retain the remaining valve caps (AB) from the charging valves (AA) on each of the collapsed
front suspension cylinders.
Note: These lines will be the oil inlet valves.
2. Ensure that swivel nuts (AD) are turned clockwise completely to close the charging valves (AA).
Typical view
Install the charging hoses to the chucks (2).
Note: Two of the charging hoses, oil outlet drain lines that were installed in Section "Collapse the Front
Suspension Cylinders" will be used to drain oil and nitrogen into an approved container. The two charging
hoses that will be installed in this section are used to pump oil into the suspension cylinders.
Turn the tee handle that is on chucks (2) counterclockwise to ensure that the charging valves will not open
during installation.
Typical view
(AA) Charging valve
4. Secure a chuck to each charging valve (AA) on the collapsed front suspension cylinders.
Note: These lines will be the oil inlet lines.
5. Connect the charging hoses and the rest of tooling (A) to chuck (2) on the inlet charging valves.
6. Open shutoff valve (3) on tool (A). Adjust the pressure on the regulator.
Reference: Refer to Illustration 7 to view shutoff valve (3).
7. Turn the two swivel nuts (AD) counterclockwise to open the inlet charging valves (AA).
8. Turn the tee handle on both chucks (2) clockwise to open valve cores (AC).
9. Begin to operate Tool (A) and pump oil into the collapsed front suspension cylinders until the oil that comes
from the drain hose on the outlet charging valve is mostly free of bubbles.
10. After the discharged oil is mostly free of bubbles, stop the pump, and turn the tee that is on chucks (2)
counter-clockwise to close the core valve on the outlet charging valves (AA).Turn the nut that is on outlet
charging valves (AA) clockwise to close the charging valves to stop any ow draining from the cylinders.
Remove chucks (2) that were connected to the outlet charging valves.
View of the front suspension cylinder
(3) Adapter
(4) Plug
Note: If performing the annual maintenance on the system, purge the grease from the suspension cylinder.
Refer to Section "Preventive Maintenance for the Sensor, the Charging Valve, and the Manifold" and
"Suspension Cylinder - Check" in your machines Operation and Maintenance Manual.
11. Proceed to Section "Charge the Front Suspension Cylinders with Oil".
Charge the Front Suspension Cylinders with Oil
Illustrative view of charging a front suspension cylinder with oil
(AA) Charging valve
Typical view
(BB) Exposed surface area measurement for the oil charging
NOTICE
If the technician is not performing the yearly maintenance and purging
the suspension cylinders now, the technician will need to install the oil
pump and inlet charge lines. Follow Steps 1 through 7 in Section
"Purge the Front Suspension Cylinders with Oil" before beginning the
next section "Charge the Front Suspension Cylinders with Oil"
1. Start tool (A) and pump oil into the collapsed front suspension cylinders to increase the cylinder height by
25.4 mm (1.0 inch).
2. Once the required height is reached on each suspension cylinder , close all valves on tooling (A), turn the tee
handles that are on chucks (2) counter-clockwise to close valve cores (AC) on the charging valve and close
the swivel nuts (AD) on the inlet charging valves.
3. Remove chucks (2) that were connected to the inlet charging valves.
4. Proceed to Section "Charge the Front Suspension Cylinders with Nitrogen".
Charge the Front Suspension Cylinders with Nitrogen
Illustrative view of charging a front suspension cylinder with nitrogen.
(AA) Charging valve
Typical view
(AA) Charging valve
1. Ensure that no oil is left in the hoses. If required, purge the charge hoses of oil.
Install one chuck (2) onto a charging valve (AA) on each of the front suspension cylinders.
Note: These valves will be the nitrogen charging valves.
2. Attach Tool (B) and the charging hoses to chucks (2).
3. Turn swivel nuts (AD) counterclockwise to open the charging valves to valve cores (AC).
4. Turn the tee handles that are on chucks (2) clockwise to open to valve cores (AC) on the charging valves.
5. To prevent a vacuum when the truck is raised later in the charging process, add approximately 1000 kPa
(150 psi) of nitrogen to the front suspension cylinders.
Note: Ensure that the valve for the nitrogen remains open and regulated to 1034 kPa (150 psi) while lifting
the truck to prevent a vacuum.
Typical example of Lift Stands (D) that are lifting a machine.
6. Place suitable lifting devices under the jacking pads at the bottom of the left and right side front suspension
castings.
Note: Refer to the lifting instructions in the "Specications for Cables, Chains, and Lifting Devices" section
within this special instruction.
7. Lift the truck until both of the front suspension cylinders are fully extended and the tires are off the ground.
Allow nitrogen to enter the suspension cylinders until the target extended charge pressure is reached.
Note: The front extended pressures are required to be equal. Refer to the target pressures that are specic to
your machine, at your site, and must be developed by you. Refer to Table 5 for a reference to the extended
charge pressures. The pressures in Table 5 are a recommended starting point.
8. After the charge is complete, close the valves on tooling (B), the tees on chucks (2) and swivel nuts (AD) on
the charging valves to stop the ow of nitrogen.
9. Remove tool (B) from the charging valves. Install the valve caps to the charging valves. Check for any leaks.
10. Tighten the valve caps to a torque of 2.5 to 3.5 Nm (22 to 31 lb in).
11. Lower the truck from the stands.
12. After both the front and rear suspension cylinders are charged, drive the machine for at least 10 minutes on a
route that includes both left and right turns. Bring the machine to a gradual stop on level ground.
Note: A sudden stop will alter the amount of exposed surface area. A sudden stop will also invalidate the
information that is used to determine if the machine needs to be serviced.
Typical view
(E) Exposed surface area measurement
Note: The wheel group shown in Illustration 39 is equipped with a stop collar. If the machine is equipped
with a stop collar on the wheel group, measure the exposed surface from the bottom of the suspension
housing to the top of the stop collar. If, the machine is not equipped with a stop collar then measure the
exposed surface from the bottom of the suspension housing to the top of the wheel spindle or hub.
13. Measure the exposed surface area and compare to the ride height listed in Table 4 and Table 5. If the
measured exposed surface area is out of tolerance, repeat Step 1 through Step 14 of this Section to add or
remove nitrogen as appropriate to achieve the desired ride height.
Note: Adjust the extended charge pressure in each cylinder by increments of +/- 138 kPa (20 psi) until the
desired ride height is achieved. After achieving the desired ride height from Table 5, record the extended
suspension cylinder charge pressures.
Note: The site recorded pressures and ride heights can be used for all trucks with the same approximate
weight and the same machine conguration.
14. Use the recorded dimensions and the extended charge pressure as a reference in this Special Instruction,
"Conditions for Servicing".
Use the recorded dimensions as a reference when you inspect the front suspension cylinders according to the
Operation and Maintenance Manual, "Maintenance Interval Schedule".
15. Calibrate the payload system. Refer to Testing and Adjusting, " Payload System - Calibrate" for instructions
to calibrate the payload system.
Preventive Maintenance for the Sensor, the Charging Valve, and the
Manifold
Note: Perform the following step only after all the oil and nitrogen charge has been removed from the
suspension cylinder.
1. This check is for the 9T-2238 Valve As and the 175-3184 Valve As. Check the maintenance records for the
last known replacement date of charging valves. If, the records indicate a year or more replace the charging
valves or the valve core. When you previously examined the charging valve and the valve was leaking,
replace the charging valve or valve core. Proceed to Step 4.
2. This check is for the 238-9928 Valve As. When you previously examined the charging valve and the valve
was leaking, replace the charging valve or valve core. Go to the next step.
3. If the truck has pressure sensors, perform Step 4 through 12. If there are no sensors on the truck, go back to
the section for purging.
4. Remove sensor (37) from manifold (38).
5. Remove check valve (39) that is positioned under sensor (37) from manifold (38).
6. Replace O-ring (40), backup ring (41), and seal (42) on check valve (39).
7. Remove manifolds (38) and O-ring seals (43) from the suspension cylinders.
8. Install new O-ring seals (43) onto manifolds (38) and install manifolds (38) onto the suspension cylinders.
9. Install check valve (39) into manifold (38).
10. Install sensor (37).
11. Refer to the Specication module for any torques.
12. Go back to the section for purging.

Worksheets
Table 4
Rear Suspension
Collapsed Exposed Extended Charge
Model Oil Height Ride Height(2)(3)
Chrome(1) Pressure(4)(5)
25.4 mm 165 13 mm
785 31.5 mm (1.25 inch) 1325 kPa (192 psi)
(1.0 inch) (6.50 0.50 inch)
25.4 mm 203 13 mm
789 76.5 mm (3.0 inch) 1500 kPa (217 psi)
(1.0 inch) (8.0 0.50 inch)
25.4 mm 203 13 mm
793 81 mm (3.19 inch) 1250 kPa (181 psi)
(1.0 inch) (8.0 0.50 inch)
25.4 mm 203 13 mm
795 72.7 mm (3.0 inch) 1200 kPa (174 psi)
(1.0 inch) (8.0 0.50 inch)
25.4 mm 203 13 mm
797 74.2 mm (3.0 inch) 1460 kPa (211 psi)
(1.0 inch) (8.0 0.50 inch)
If the difference between outside ambient temperature and the temperature in the shop is greater than 11 C
(20F), add or subtract 2.54 mm (0.10 inch) for every 5.5 C (10 F) difference
(1) Approximate
(2) Recommended
(3) Ride heights are not required to be equal, just within the tolerance of the specication
(4) Reference Only
(5) Both rear suspension cylinders should have equal extended charge pressure
Table 5
Front Suspension
Collapsed Exposed Extended Charge

Model Oil Height Ride Height(2)(3)
Chrome(1) Pressure(4)(5)
25.4 mm 248 20 mm
785 17 mm (0.67 inch) 1800 kPa (260 psi)
(1.0 inch) (10 0.80 inch)
25.4 mm 248 20 mm
789 20 mm (0.79 inch) 1800 kPa (260 psi)
(1.0 inch) (10 0.80 inch)
25.4 mm 248 20 mm
793 20 mm (0.79 inch) 2070 kPa (300 psi)
(1.0 inch) (10 0.80 inch)
25.4 mm 248 20 mm
795 20 mm (0.79 inch) 1900 kPa (276 psi)
(1.0 inch) (10 0.80 inch)
25.4 mm 248 20 mm
797 20 mm (0.79 inch) 2100 kPa (305 psi)
(1.0 inch) (10 0.80 inch)
If the difference between outside ambient temperature and the temperature in the shop is greater than 11 C
(20F), add or subtract 2.54 mm (0.10 inch) for every 5.5 C (10 F) difference
(1) Approximate
(2) Recommended
(3) Ride heights are not required to be equal, just within the tolerance of the specication
(4) Reference Only
(5) Both front suspension cylinders should have equal extended charge pressure
After a rebuild or an assembly of a suspension cylinder, the requirements for the approximate amount of oil is
listed in Table 6.
Table 6
Total Oil Requirements for Suspension Cylinders (If bled completely)
Truck Model Front Suspension Cylinder Rear Suspension Cylinder
784, 785 47.6 L (12.6 US gal) 25.9 L (6.8 US gal)

789 60.1 L (15.9 US gal) 35.6 L (9.4 US gal)
793 74.5 L (19.7 US gal) 35.6 L (9.4 US gal)
795 110 L (29.1 US gal) 48.5 L (12.8 US gal)

797 110 L (29.1 US gal) 48.5 L (12.8 US gal)
Copyright 1993 - 2017 Caterpillar Inc. Tue Aug 29 2017 16:57:52 GMT-0300 (CLST)
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29/8/2017 Bsqueda del medio - SEHS9411 - Servicing the Suspension Cylinders for Large Off-Highway Trucks {0756, 7200,

0756, 7200, 7201, 7201, 7201, 7213}

Servicing the Suspension Cylinders for Large Off-Highway Trucks

Better machine ride

Improved structural durability

Improved shock absorption and operator comfort

Higher suspension cylinder reliability

Improved ability to maintain the intended level of controllability

Better operating efciency

Increased accuracy of the payload measurement system

The signal word WARNING has the following meanings:

Your Safety Is Involved !

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

Improper operation, lubrication, maintenance or repair of this product

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

Read all Warning labels on the suspension cylinders before servicing.

The vehicle must be on level ground before releasing the nitrogen

Do not stand under the machine during suspension cylinder charging,

Failure to heed this Warning could lead to injury or death.

methods of identication to tell the difference between nitrogen

Never use an adapter to connect your nitrogen charging group to a valve

When applying an oil charge or a nitrogen charge with the machine on

Suspension groups should only be serviced by properly trained

Refer to Special Publication, NENG2500, "Dealer Service Tool

Dispose of all uids according to local regulations and mandates.

Always observe the list of basic precautions that follows:

Mounting and Dismounting

Specications for Cables, Chains, and Lifting Devices

Hot Fluids and Parts

Caterpillar Channel 1 Video

Note: A CWS login is required to access CaterpillarChannel 1.

Conditions for Servicing

Suspension cylinder shows signs of leakage.

The travel of the suspension cylinder rod is limited.

Ensure that the fuel tank is full of fuel.

3.78 L (1 US gal) 37.89 mL (1.28 oz)

B 175-5507 Nitrogen Charging Group(1) 1

C 175-7410 Nitrogen Charging Fitting Gp(1) 1

Procedure for the Rear Suspension Cylinders

Note: These valves will be the outlet valves.

Install the charging hoses to chuck (2).

Note: These lines will be the oil outlet drain lines.

7. Mark the location of the collapsed suspension cylinders.

Purge the Rear Suspension Cylinders with Oil

Note: These valves will be the inlet valves.

Install the charging hoses to the chucks (2).

Note: These lines will be the oil inlet lines.

Reference: Refer to Illustration 7 to view shutoff valve (3).

Charge the Rear Suspension Cylinders with Oil

4. Proceed to Section "Charge the Rear Suspension Cylinders with Nitrogen"

Charge the Rear Suspension Cylinders with Nitrogen

2. Attach Tool (B) and the charging hoses to chucks (2).

6. Place a suitable lifting device under the hoist tube.

11. Lower the truck from the stands.

Procedure for the Front Suspension Cylinders

Note: These valves will be the outlet valves.

Install the charging hoses to chuck (2)

Note: These lines will be the oil outlet drain lines.