17/8/23, 16:22 SIS 2.

Servicing the Suspension Cylinders for Off-Highway Trucks {0756, 7200, 7201, 7201,
2023/06/22
7201, 7213, 7213} (REHS4445-21)

SMCS - 0756, 7200, 7201, 7213 i09797475

Off-Highway Truck/Tractor
PIP
769D (S/N: BBB1-UP; 5TR1-UP; 5SS1-UP)
770 (S/N: BZZ1-UP)
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202 1117
3
20: 08/1 035
770G (S/N: KD21-UP; KDH1-UP; ECM1-UP; ECX1-UP)
/ 9
772 (S/N: RLB1-UP)
2
RE 2:03- 7
772G (S/N: KE31-UP; LTS1-UP; KEX1-UP; LTX1-UP)
773 (S/N: FKT1-UP)
773D (S/N: NBJ1-UP; 7ER1-UP; 7CS1-UP)
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© 2 S444 04:00
023 5
773E (S/N: BDA1-UP; PRB1-UP; KEG1-UP; ASK1-UP; DJS1-UP)
773F (S/N: EED1-UP; EXD1-UP) Cat
776C (S/N: 2TK1-UP) erp
illa
7W81-UP; 7W91-UP) rI
777 (S/N: 7M21-UP; 7W21-UP; 7M31-UP; 7W31-UP; 7M41-UP; 7W41-UP; 7M61-UP; 7W61-UP;

nc.
777C (S/N: 4XJ1-UP)
777D (S/N: AGC1-UP; FKR1-UP; 3PR1-UP)
777E (S/N: KYD1-UP; KZD1-UP; KDP1-UP; KDZ1-UP)
777F (S/N: JRP1-UP; JXP1-UP)
777G (S/N: T5A1-UP; TNM1-UP; RDR1-UP; T4Y1-UP)
Quarry Truck
771D (S/N: BCA1-UP; 6JR1-UP; 6YS1-UP)
773G (S/N: MWH1-UP; JWS1-UP; T5S1-UP; T5T1-UP)
775D (S/N: 6KR1-UP; 8AS1-UP)
775E (S/N: BEC1-UP)
775F (S/N: EYG1-UP; DLS1-UP)
775G (S/N: T5F1-UP; RFM1-UP; MJS1-UP; T5W1-UP)

Revision History:
Table 1

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Revision Summary of Changes

21 Added S/N:FKT machine serial number prefix.
20 Added new 777 serial number prefixes.
19 S/N:KYD and ; S/N:KZD prefix added.
18 Added video link and QR code.
Significant Revision.
17 Reworked Table 6.
Significant procedure and step adjustments.

Introduction
This Special Instruction contains the information and the procedure that should be used for purging
the oil and nitrogen from the suspension cylinders on Off-Highway Trucks. 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. Trucks
may have different weight configurations due to differences in dump body, liners, engines, custom
attachments. The different weight configurations can cause varied carry pressures.

The suspension system on Off-Highway Trucks consists of four suspension cylinders. The benefits
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 efficiency

Increased accuracy of the payload measurement system

Note: These procedures are to maintain the correct suspension cylinder charge and the correct ride
height.

Reference Section
Reference: Special Instruction, REHS9345 , "Procedure to Troubleshoot the Loss of Nitrogen
Precharge or Oil from Suspension Cylinders"

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Reference: Reuse & Salvage Guidelines, NEHS0742 , "Assembly of 175-5507 and 361-3889
Nitrogen Charging Groups and 175-7410 Auxiliary Fitting Group"

Illustration 1 g06471531

Reference: For more information, refer to "Servicing the Suspension Cylinders for Certain Quarry
and Off-Highway Trucks" on Caterpillar Channel1.

Note: Click or copy the following link into a web browser (a CWS login is required to access
Caterpillar Channel1), or scan the following QR code using a QR enabled device.

https://channel1.mediaspace.kaltura.com/media/t/1_ohmqpyh0

Illustration 2 g06695259

Safety Information
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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 3 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.

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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.

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.

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.

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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.

High Pressure Cylinder. Do not remove any grease fitting, 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.

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).

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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.

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, PERJ1017, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain
fluids on Cat® products.

Dispose of all fluids according to local regulations and

mandates.

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

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Illustration 4 g00037860
Use steps and hand holds whenever you mount the machine. Use steps and hand holds whenever
you dismount the machine. Before you mount the machine, clean the step and the hand holds.
Inspect the step and hand holds. 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 hand holds.

Note: Three-points contact must be used when mounting or dismounting the machine.

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 hand holds 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 to lift components. Refer to the manufacturer's
weight's 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 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.

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Illustration 5 g00629745
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 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 to prevent being sprayed by pressurized liquids. When the machine has 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. If there is 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.

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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 nitrogen, 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. Loose hydraulic lines, tubes, and hoses 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 nitrogen or water can cause personal injury. When pressure nitrogen or water is used
for cleaning, wear a protective face shield, protective clothing, and protective shoes. The
maximum nitrogen 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.

Definitions
Carry or On the Ground Pressure - The Carry Pressure is the pressure seen in the suspension
cylinders when the truck is on level ground

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 defined by the measurement
of the exposed chrome length 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 measured as the suspension cylinder pin to pin length.

Rolling Stop - Position the machine on level ground. Bring the machine to a smooth gradual stop
without using the brakes or retarder. A sudden stop will alter the exposed chrome length. A sudden
stop will also invalidate the information that is used to determine if the machine needs to be
serviced.

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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 empty weight of the truck changes more than 22241 N (5000 lb).

The ride is rough or the suspension cylinders are at full extension when the truck is empty.

The ride height of each cylinder is not within ± 13 mm (± .5 inch) of the correct height of that
vehicle.

Refer to the Operation and Maintenance Manual, "Maintenance Interval Schedule" 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.

Oil Requirements
Table 2
Required Oil
Cat TDTO SAE 10W(1)
Cat HYDO Advanced 10 SAE 10W(2)
(1) Cat TDTO with friction modifier is preferred
(2) Cat HYDO is an acceptable substitute without friction modifier

Table 3
Friction Modifier Mixing Instructions (99% Suspension Oil,
Friction Modifier
1% Friction Modifier)
Part Number Suspension Oil Friction Modifier
3.78 L (1 US gal) 37.89 mL (1.28 oz)
1U-9891 Hydraulic Oil Additive
(1 qt container of 100% 18.9 L (5 US gal) 189.4 mL (6.4 oz)
Friction Modifier)
208 L (55 US gal) 2083.8 mL (70.4 oz)

Note: Friction modifier must be mixed to the suspension oil before the suspension cylinders are
charged with oil.

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Required Parts
Table 4

Required Parts
Item Qty Part Number Part Name
- 4 440-2668 Valve Core

Required Tools
Table 5
Required Tools
Item Qty Part Number Part Name
A 1 9U-5617 Oil Refill Pump(1)
B 1 175-5507 Nitrogen Charging Group(1)
C 1 175-7410 Nitrogen Charging Fitting Gp(1)
D 1 7F-8240 Hand Tool (TIRE VALVE STEM REPAIR)
E 2 FT1680 Gauge Block(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) Fabricated

Reference: Special Instruction, NEHS0742 for assembly instructions for tool (B) and tool (C).

NOTICE
Do not reuse a 440-2668 Valve Core. If a 440-2668 Valve Core
is removed, replace with a new 440-2668 Valve Core.

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Illustration 6 g00295778
Tool 9U-5617 Oil Refill Pump (A)
( 1) Shutoff valve for the regulator
(2) 7S-5106 Chuck
(2) 1S-8938 Chuck
(3) Shutoff valve
(4) Charging hoses

Illustration 7 g01058817
Tool 175-5507 Nitrogen Charging Group (B)
( 5) 162-4147 Hose As
(6) 8S-4600 Fitting
(7) 8S-1506 Coupling
(8) 162-4146 Regulator
(2) 7S-5106 Chuck
(2) 1S-8938 Chuck
(9) 8T-0859 Pressure Gauge
(10) 8S-4599 Coupling
(11) 2S-5244 Fitting
(12) 1S-8937 Needle Valve
(13) 2D-7325 Pipe Tee
(14) 1S-8941 Hose As

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Illustration 8 g01433219
Tool 175-7410 Nitrogen Charging Fitting Gp (C)
( 15) 8S-7169 Coupling
(16) 1S-8941 Hose As
(2) 7S-5106 Chuck
(2) 1S-8938 Chuck
(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. Pressure gauge (9) is used to check the pressure in the cylinder
before the charging procedure is performed.

Fabrication of Charge Block (E)

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Illustration 9 g06556298
Illustration for the FT680 Gauge block
(D1) 215 ± 0.5 mm (8.50 ± 0.02 inch)
(D2) 170 ± 0.5 mm (6.69 ± 0.02 inch)
(D3) 8 ± 1 mm (0.3 ± 0.04 inch)
(D4) 50 ± 2 mm (2.0 ± 0.08 inch)
(D5) 40 ± 2 mm (1.6 ± 0.08 inch)
(D6) 25 ± 1 mm (1.0 ± 0.04 inch)

1. Using SAE 1020 steel, fabricate 2 gauge blocks. Refer to Illustration 9 for dimensions.

Note: Height dimension (D1) is used for 776, and 777. Height dimension (D2) is used for 769, 770,
771, 772, 773, and 775.

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.
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Ensure that the fuel tank is full of fuel.

Drive the machine for at least 20 minutes to warm the suspension cylinders. Bring the machine to a
smooth gradual stop on level ground, without using the brakes or retarder before measuring the ride
height or servicing the suspension cylinders.

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.

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 difficult 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. The chrome can be polished to remove the stain. Eventually, the wear band should
become soaked by oil and grease and the blackening should decrease.

Charging Process Flowchart

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Illustration 10 g06560030

Identify Suspension Cylinders to be Charged

When charging suspension cylinders, any changes done to one suspension cylinder affects the
other three. This is the reason a final check and possible adjustment of ride height is required. To
minimize the affect, suspension cylinders should always be charged in pairs. The pairs consist of
either both front or both rear suspension cylinders. In addition, if the "Truck Payload Measurement
System" (TPMS ) accuracy has declined to an unacceptable level, it may be necessary to charge all
4 suspension cylinders.

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One or both rear suspension cylinders needs charging – Charge both rear suspension cylinders

One or both front suspension cylinders needs charging - Charge both front suspension
cylinders

At least one front and at least one rear suspension cylinder needs charging – Charge all 4
suspension cylinders

TPMS accuracy has declined to an unacceptable level – Charge all 4 suspension cylinders

Procedure to Collapse Suspension Cylinders

Collapse the Suspension Cylinders to be Charged
Note: If the front suspension cylinders are being serviced, collapse both front suspension cylinders
at the same time. If the rear suspension cylinders are being serviced, collapse both rear suspension
cylinders at the same time.

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 filled with a known amount of oil.

Illustration 11 g06556794
Views of collapsing front suspension cylinders with all valves open
(AA) Charging valve
(2) 7S-5106 Chuck or 1S-8938 Chuck

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Illustration 12 g06556438
Views of collapsing rear suspension cylinders with all valves open
(AA) Charging valve
(2) 7S-5106 Chuck or 1S-8938 Chuck

Illustration 13 g06556815
Typical view front suspension
(AA) Charging valve
(AB) Valve cap

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Illustration 14 g06556568
Typical view rear suspension
(AA) Charging valve
(AB) Valve cap

1. Remove and retain one valve cap (AB) from a charging valve (AA) on both of the suspension
cylinders to be charged.

Illustration 15 g03775735
Typical view
(2) 7S-5106 Chuck or 1S-8938 Chuck

2. Locate two chucks (2) that are part of the nitrogen charging group.
Install the charging hoses to chuck (2).

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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.

Illustration 16 g03782591
Typical view front suspension
(AA) Charging valve
(2) 7S-5106 Chuck or 1S-8938 Chuck

Illustration 17 g03782352
Typical view rear suspension
(AA) Charging valve
(2) 7S-5106 Chuck or 1S-8938 Chuck
3. Install one chuck (2) onto a charging valve (AA) on both of the suspension cylinders.

4. Turn the tee handle that is on chucks (2) clockwise to depress the core valve on charging
valves (AA).

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Use a wrench to hold charging valve (AA) and a second wrench to turn the swivel nut that is on
charging valve (AA) counterclockwise to open charging valves (AA).

Note: Opening charging valves (AA) allows oil and nitrogen to flow through the charging valves
so that the suspension cylinders will collapse completely.
5. Let oil and nitrogen flow into the suitable container until the suspension cylinders have
collapsed.

Illustration 18 g06484471
typical view of front cylinder
(BB) Exposed chrome length front suspension cylinder

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Illustration 19 g03784690
Typical view rear cylinders
(B) Pin to pin dimension rear suspension cylinders
6. After the suspension cylinders have collapsed completely, leave the charging valves in the
open position for 5 to 10 minutes to allow the pressure in the suspension cylinders to equalize
with atmosphere.
Verify that the suspension cylinders have collapsed completely. For the front suspension
cylinders, measure the exposed chrome height (BB) and compare to dimension given in Table
6. For the rear suspension cylinders, measuring the pin to pin dimension (B) and compare to
dimension given in Table 7.

7. After the pressure has equalized, use a wrench to hold charging valve (AA) and a second
wrench to turn the swivel nut that is on charging valve (AA) clockwise to close charging valves
(AA). Do not overtighten the swivel nut.

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Also, turn the tee that is on chucks (2) counterclockwise to close the core valve on charging
valves (AA).
8. Proceed to Section "Charge the Suspension Cylinders with Oil".

Charge the Suspension Cylinders with Oil

Illustration 20 g06557545
View of purging the front suspension cylinders of oil with all valves open
(A) 9U-5617 Oil Refill Pump
(AA) Charging valve
(2) 7S-5106 Chuck or 1S-8938 Chuck

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Illustration 21 g06556647
Illustrative view of purging the rear suspension cylinders of oil with all valves open
(A) 9U-5617 Oil Refill Pump
(AA) Charging valve
(2) 7S-5106 Chuck or 1S-8938 Chuck

Illustration 22 g06556815
Typical view front suspension cylinder
(AA) Charging valve
(AB) Valve cap

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PIP
-
202 1117
3
20: 08/1 035
/ 9
2
RE 2:03- 7
H
© 2 S444 04:00
023 5
Cat
erp
illa
Illustration 23
Typical view rear suspension cylinder
rI
g06556568
nc.
(AA) Charging valve
(AB) Valve cap

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Illustration 24 g03867092
(AA) Charging valve - Installation torque 13.6 ± 0.5 N·m (120.37 ± 4.42 lb in)
(AB) Valve cap - Installation torque 2.5 ± 0.5 N·m (22.12 ± 4.42 lb in)
(AC) Valve core - Installation torque 0.5 ± 0.1 N·m (4.42 ± 0.88 lb in)
(AD) Swivel nut - Closure torque 6.8 ± 0.5 N·m (60.18 ± 4.42 lb in)

1. Remove and retain the valve caps (AB) from both charging valves (AA) on both of the
suspension cylinders.

2. Ensure that swivel nut (AD) is turned clockwise completely to close charging valve (AA).
Remove and discard valve core (AC) from one charging valve (AA) on both suspension
cylinder.

Note: Removing valve core (AC) will help to keep the oil from aerating while pumping oil into
the cylinders.

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Note: The charging valves that had valve cores (AC) removed are the inlet valves. The
charging valves that did not have valve cores (AC) removed are the outlet valves.

Illustration 25 g03775735
Typical view
(2) 7S-5106 Chuck or 1S-8938 Chuck
3. Locate four chucks (2) that are part of the nitrogen charging group.
Install the charging hoses onto chucks (2).

Note: Two of the charging hoses will be used to drain oil into an approved container. Two of the
charging hoses will be 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.

Illustration 26 g06556815
Typical view front suspension cylinder
(AA) Charging valve

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(AB) Valve cap

Illustration 27 g03782380
Typical view of rear suspension cylinder
(AA) Charging valve
(2) 7S-5106 Chuck or 1S-8938 Chuck
4. Secure a chuck (2) to each charging valve (AA) on both suspension cylinders.

5. Connect the charging hoses and the rest of the tooling from Oil Refill Pump (A) to chucks (2) on
the charging valves that had valve cores (AC) removed.

6. Connect drain hoses to chucks (2) on the charging valves that did not have valve cores (AC)
removed.

7. Open shutoff valves (3) on Tool (A).

Reference: Refer to Illustration 6 to view shutoff valve (3).

8. Turn the tee handle on all four chucks (2) clockwise to open valve cores (AC).
Note: Two valve cores (AC) were previously removed, and the tee handle should still be turned
clockwise.

9. Turn all swivel nuts (AD) counterclockwise to open charging valves (AA).

10. Begin to operate Tool (A) and pump oil into both suspension cylinders and out the drain hoses.
Continue to pump oil into the suspension cylinders until the oil that comes from the drain hose
on the outlet charging valve is mostly free of bubbles.

11. After the discharged oil is mostly free of bubbles, stop Tool (A) and close swivel nuts (AD) on
the outlet charging valves to stop any flow draining from the cylinders.

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Illustration 28 g06557692
View of charging the front suspension cylinders with oil
(A) 9U-5617 Oil Refill Pump
(AA) Charging valve
(2) 7S-5106 Chuck or 1S-8938 Chuck

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Illustration 29 g06557722
View of charging the rear suspension cylinders with oil
(A) 9U-5617 Oil Refill Pump
(AA) Charging valve
(2) 7S-5106 Chuck or 1S-8938 Chuck

Illustration 30 g06484471
Typical view of front suspension cylinder
(BB) Exposed chrome length

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Illustration 31 g03784710
Typical view rear suspension cylinder
(B) Pin to pin dimension
12. On both outlet line chucks, turn the tee handle (2) counter clockwise to close valve cores (AC).
Remove discharge line chucks from both cylinders.

13. Remove both inlet chucks (2). Install two new 440-2668 Valve Core into the charging valves.
Tighten new valve cores to 0.5 ± 0.1 N·m (4.42 ± 0.88 lb in). Reinstall both inlet chucks (2).

14. Start tool (A) and pump oil into each suspension cylinder to increase the cylinder height to the
oil charged dimension shown in Table 6 for the front suspension cylinders and Table 7 for the
rear suspension cylinders.
Note: If one suspension cylinder reaches oil charged height before the other suspension
cylinder, close the shutoff valve for that suspension cylinder and continue injecting oil into the
other suspension cylinder until the oil charged height is achieved.

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15. Once the required cylinder charged oil height is reached, close all valves on tooling (A), close
all swivel nuts (AD) on the charging valves, and turn all the tees on all chucks (2)
counterclockwise to close valve cores (AC) on the charging valves.

16. If charging both front suspension cylinders or both rear suspension cylinders, proceed to
Section "Charge Suspension Cylinders with Nitrogen"
If charging all 4 suspension cylinders and all suspension cylinders have been charged with oil,
proceed to charge the rear suspension cylinders following procedure in Section "Charge
Suspension Cylinders with Nitrogen".

If charging all 4 suspension cylinders and only the front suspension cylinders have been
charged with oil, proceed to"Procedure to Support Front Suspension Cylinders on Gauge
Blocks".

Procedure to Support Front Suspension Cylinders on Gauge

Blocks

Illustration 32 g06558368
View of front suspension cylinders
(AA) Charging valve
(2) 7S-5106 Chuck or 1S-8938 Chuck

1. If chucks (2) were removed, install one chuck (2) onto a charging valve (AA) on each of the rear
suspension cylinders.
Note: Make sure that no oil is left in the hoses.

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

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3. Close all the valves on tooling (B) . Turn the tees on chucks (2) counterclockwise, and swivel

PIP
nuts (AD) clockwise on the charging valves.

-
202 1117
4. Adjust the pressure on the regulator. Refer to Table 6.

3
20: 08/1 035
/ 9
Note: This will not be the final pressure in the suspension cylinders. It is the pressure to raise
the cylinders to the ride height. The final pressure will be lower than the pressure needed to

2
raise the cylinders to ride height. The final pressure is determined by the weight of the truck

RE 2:03- 7
supported by the suspension cylinder.

H
© 2 S444 04:00
5. Turn swivel nuts (AD) counterclockwise on the charging valve, and turn the tee on chucks (2)
clockwise to open valve cores (AC) and the tooling to allow nitrogen to enter the suspension

023 5
cylinders. When the cylinders are approximately 12 mm (0.5 inch) below ride height, turn the
tee on chucks (2) counterclockwise to close valve cores (AC). The suspension cylinders will

Cat
continue to rise for a few minutes. Insert the gauge blocks with chamfer towards the seal to

erp
avoid damaging the seal. If necessary add more nitrogen to insert the gauge blocks.

illa
Note: The full gauge block length is used for the 777. The shorter, notched, length is used for
769 to 775.
rI
6. Turn the tee handle that is on chucks (2) clockwise to depress the core valve on charging nc.
valves (AA). Use a wrench to hold charging valve (AA) and a second wrench to turn the swivel
nut that is on charging valve (AA) counterclockwise to open charging valves (AA).
When the suspension cylinders are supported by the gauge blocks, use a wrench to hold
charging valve (AA) and a second wrench to turn the swivel nut that is on charging valve (AA)
clockwise to close charging valves (AA). Do not overtighten the swivel nut. Also, turn the tee
on chucks (2) counterclockwise to close the core valve on charging valves (AA).

Note: Opening charging valves (AA) allows nitrogen to flow through the charging valves so that
the suspension cylinders will collapse.

7. Remove tool (B) from the charging valves.

8. Perform "Procedure to Collapse Suspension Cylinders" on rear suspension cylinders.

Procedure to Remove Gauge Blocks

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Illustration 33 g06558368
View of front suspension cylinders
(AA) Charging valve
(2) 7S-5106 Chuck or 1S-8938 Chuck

1. Raise the body. Try to remove the gauge blocks from the front suspension cylinders. If the
gauge blocks are removed, skip to Step 8. Otherwise, continue with Step 2.

2. If chucks (2) were removed, install one chuck (2) onto a charging valve (AA) on both of the rear
suspension cylinders.
Note: Make sure that no oil is left in the hoses.

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

4. Close all the valves on tooling (B). Turn the tees on chucks (2) counterclockwise, and swivel
nuts (AD) clockwise on the charging valves.

5. Adjust the pressure on the regulator. Refer to Table 6 for correct Regulator Pressure Setting.
Note: This is not the final pressure in the suspension cylinders. It is the pressure to raise the
cylinders to the ride height. The final pressure will be lower than the pressure needed to raise
the cylinders to ride height. The final pressure is determined by the weight of the truck
supported by the suspension cylinder.

6. Turn swivel nuts (AD) counterclockwise on the charging valve, and turn the tee on chucks (2)
clockwise to open valve cores (AC) and the tooling to allow nitrogen to enter the suspension
cylinders.
Note: Add enough nitrogen for the gauge blocks to be removed.

7. After the suspension cylinders gauge blocks have been removed, close the valves on tooling
(B) , turn the tee on chucks (2) counterclockwise to close valve cores (AC), and turn swivel nut

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(AD) clockwise on the charging valve to stop the flow of nitrogen.

8. Lower the body.
Note: The truck will be lower than when the truck was supported by the gauge blocks.
Therefore, ensure that there is nothing under the truck that could be damaged with the body is
lowered.

9. Proceed to Section "Charge Suspension Cylinders with Nitrogen" to apply final nitrogen charge
to the front suspension cylinders.

Charge Suspension Cylinders with Nitrogen

Illustration 34 g06558368
View of front suspension cylinders
(AA) Charging valve
(2) 7S-5106 Chuck or 1S-8938 Chuck

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Illustration 35 g06558432
Illustrative view of charging the rear suspension cylinders with nitrogen with all valves open
(AA) Charging valve
(2) 7S-5106 Chuck or 1S-8938 Chuck

Illustration 36 g03782738
Typical view front suspension cylinder
(AA) Charging valve
(AB) Valve cap

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Illustration 37 g03782392
Typical view
(AA) Charging valve
(2) 7S-5106 Chuck or 1S-8938 Chuck

1. If chucks (2) were removed, install one chuck (2) onto a charging valve (AA) on both of the
suspension cylinders.
Note: Make sure that no oil is left in the hoses.

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

3. Close all the valves on tooling (B). Turn the tees on chucks (2) counterclockwise, and swivel
nuts (AD) clockwise on the charging valves.

4. Adjust the pressure on the regulator. Refer to Table 6 for the regulator pressure when charging
the front suspension cylinders. Refer to Table 7 for the regulator pressure when charging the
rear cylinders.
Note: This will not be the final pressure in the suspension cylinders. It is the pressure to raise
the cylinders to the ride height. The final pressure will be lower than the pressure needed to
raise the cylinders to ride height. The final pressure is determined by the weight of the truck
supported by the suspension cylinder.

5. Determine the correct ride height, including temperature adjustment, if needed. Refer to Table 6
for correct front cylinder ride height. Refer to Table 7 for the correct rear cylinder ride height.

a. Measure the difference between the outside ambient temperature and the temperature of
the service shop. If the temperature difference is less than 11° C (20° F), no adjustment is
needed. Refer to Table 6 for the final front suspension cylinder chrome dimension for your
machine. Refer to Table 7 for the final pin to pin dimension for your machine.

b. If this temperature is greater than 11° C (20° F), you will need to adjust the final pin to pin
dimension. Add 2.54 mm (0.100 inch) to the rear suspension pin to pin dimension for every
5.5° C (10° F) of temperature difference. Add 2.54 mm (0.100 inch) to the front suspension
cylinder exposed chrome dimension for every 5.5° C (10° F) of temperature difference.

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Note: Estimate the temperature difference to the nearest 5.5° C (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
Example of corrected guidelines for the nitrogen charging procedure ... 1015 mm + 23.1
mm (.90 inch) = 1038.1 mm (40.87 inch)
6. Turn swivel nuts (AD) counterclockwise on the charging valve, and turn the tee on chucks (2)
clockwise to open valve cores (AC) and the tooling to allow nitrogen to enter the suspension
cylinders. When the cylinders are approximately 25 mm (1 inch) below ride height, turn the tee
on chucks (2) counterclockwise to close valve cores (AC). Allow a few minutes for the
suspension cylinders to stop rising.

7. If after a few minutes, the ride height is still low, then turn the tee on chucks (2) clockwise to
open valve cores (AC) until the correct ride height is reached.
Once the correct ride height is achieved, turn the tee on chucks (2) counterclockwise to close
valve cores (AC) and stop the flow of nitrogen.

If one side reaches proper ride height before the other side, then close the valve on tooling (B)
for the side with proper ride height and continue to add nitrogen to the other side until proper
ride height is reached.

8. After the correct right height is reached, close the valves on tooling (B), turn the tee on chucks
(2) counterclockwise to close valve cores (AC), and turn swivel nut (AD) clockwise on the
charging valve to stop the flow of nitrogen.

9. Remove tool (B) from the charging valves.

10. Check for leaks.

11. Reinstall the previously removed valve caps to the charging valves. Tighten the valve cap to a
torque of 2.5 ± 0.5 N·m (22.12 ± 4.42 lb in).

12. If charging all suspension cylinders and front suspension cylinders have not been changed with
Nitrogen, proceed to Procedure to add initial nitrogen charge in the suspension cylinders
supported by on gauge blocks.
If charging only rear suspension cylinders , proceed to "Verification Check and Final
Adjustments".

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If charging front suspension cylinders , proceed to "Verification Check and Final Adjustments".

Verification Check and Final Adjustments

1. After the 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 smooth gradual stop on
level ground, without using the brakes or retarder.
Note: A sudden stop will alter the exposed chrome length. A sudden stop will also invalidate the
information that is used to determine if the machine needs to be serviced.

Illustration 38 g06484481
Typical view
(BB) Exposed chrome length measurement

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Illustration 39 g03784710
Typical view
(B) Pin to pin dimension
2. Measure the front suspension cylinder ride height chrome length. Compare the measurement
to the ride height listed in Table 6. If the measured exposed surface area is out of tolerance,
add or remove nitrogen to achieve the proper ride height.

3. Measure the rear suspension cylinder pin to pin dimension. Compare the measurement to the
ride height listed in Table 7. If the measured exposed surface area is out of tolerance, add or
remove nitrogen to achieve the proper ride height.

4. If the ride height adjustment was performed in Step 2 or Step 3, repeat Step 1 through Step 4
until a proper ride height is achieved.

5. Perform the payload calibration as instructed. It is important to follow the procedure and allow
the machine to roll to a stop on smooth and level ground when the calibration procedure is
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being performed.

Table 6
Front Suspension Cylinder Charging Specifications
Collapsed Oil Charged Regulator
Ride Height Chrome
Model Oil Volume Chrome Chrome Pressure
Length (Ground)
Length(1) Length Setting(2)
14 L
20 mm 45.4 mm 170 ± 13 mm 2755 kPa
769 (3.7 US gal)
(0.79 inch) (1.79 inch) (6.7 ± 0.5 inch) (400 psi)
(3)

14 L
20 mm 45.4 mm 170 ± 13 mm 2755 kPa
771 (3.7 US gal)
(0.79 inch) (1.79 inch) (6.7 ± 0.5 inch) (400 psi)
(3)

12 L
18 mm 43.4 mm 170 ± 13 mm 3450 kPa
770 (3.2 US gal)
(0.71 inch) (1.71 inch) (6.7 ± 0.5 inch) (500 psi)
(4)

12 L
18 mm 43.4 mm 170 ± 13 mm 3450 kPa
772 (3.2 US gal)
(0.71 inch) (1.71 inch) (6.7 ± 0.5 inch) (500 psi)
(4)

12 L
21 mm 46.4 mm 170 ± 13 mm 4480 kPa
773 (3.2 US gal)
(0.83 inch) (1.83 inch) (6.7 ± 0.5 inch) (650 psi)
(4)

12 L
21 mm 46.4 mm 170 ± 13 mm 4480 kPa
775 (3.2 US gal)
(0.83 inch) (1.83 inch) (6.7 ± 0.5 inch) (650 psi)
(4)

29 L
8 mm 20.7 mm 216 ± 13 mm 3620 kPa
776 (7.6 US gal)
(0.31 inch) (0.81 inch) (8.5 ± 0.5 inch) (525 psi)
(5)

29 L
8 mm 20.7 mm 216 ± 13 mm 3620 kPa
777 (7.6 US gal)
(0.31 inch) (0.81 inch) (8.5 ± 0.5 inch) (525 psi)
(5)
(1) Approximate
(2) This is the approximate pressure needed to raise the truck. This will not be the final pressure in the suspension
cylinders. The final pressure will be lower than the pressure needed to raise the truck to ride height. If the truck does
not rise with this pressure, slowly increase the pressure until the truck starts to rise.
(3) 140 mL (4.76 oz) Friction Modifier required
(4) 120 mL (4.08 oz) Friction Modifier required
(5) 290 mL (9.86 oz) Friction Modifier required

Table 7
Rear Suspension Cylinder Charging Specifications
Collapsed Pin Oil Charged Regulator
Ride Height Pin to
Model Oil Volume to Pin Pin to Pin Pressure
Pin (Ground)
Length(1) Length Setting(2)

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12 L
776 mm 801 mm 910 ± 13 mm 1725 kPa
769 (3.2 US gal)
(30.50 inch) (31.50 inch) (35.8 ± 0.5 inch) (250 psi)
(3)

12 L
776 mm 801 mm 910 ± 13 mm 1725 kPa
771 (3.2 US gal)
(3) PIP
(30.50 inch) (31.50 inch) (35.8 ± 0.5 inch) (250 psi)

770
9L
(2.4 US gal)
681 mm -
202 1117 706 mm 780 ± 13 mm 1725 kPa

9
(27 inch) (28 inch) (30.7 ± 0.5 inch) (250 psi)
(4)

9L 3
20: 08/1 035
/
2
681 mm 706 mm 780 ± 13 mm 1725 kPa

RE 2:03- 7
772 (2.4 US gal)
(27 inch) (28 inch) (30.7 ± 0.5 inch) (250 psi)
(4)

773
12 L
(3.2 US gal)
(3)
H
© 2 444 4:00
887 mm
S
(35 inch) 0 912 mm
(36 inch)
1015 ± 13 mm
(40 ± 0.5 inch)
2415 kPa
(350 psi)

775
12 L
(3.2 US gal) 023 5
887 mm 912 mm 1015 ± 13 mm 2415 kPa
(3)
(35 inch)
Cat (36 inch) (40 ± 0.5 inch) (350 psi)

16 L
915 mm erp 928 mm 1030 ± 13 mm 2415 kPa
776 (4.2 US gal)
(36 inch)
illa (36.5 inch) (40.5 ± 0.5 inch) (350 psi)

rI
(5)

777
16 L
(4.2 US gal)
(5)
915 mm
(36 inch)
928 mm
(36.5 inch)
1030 ± 13 mm
(40.5 ± 0.5 inch) nc. 2415 kPa
(350 psi)
(1) Approximate
(2) This is the approximate pressure needed to raise the truck. This will not be the final pressure in the suspension
cylinders. The final pressure will be lower than the pressure needed to raise the truck to ride height. If the truck does
not rise with this pressure, slowly increase the pressure until the truck starts to rise.
(3) 120 mL (4.08 oz) Friction Modifier required
(4) 90 mL (3.06 oz) Friction Modifier required
(5) 160 mL (5.4 oz) Friction Modifier required

Off-Highway Truck Suspension Charging Quick

Reference Guide
Suspension charging quick reference guide and checklist. For more information on each step, see
detailed instructions.

Model:_____________________________

Serial Number:______________________

1. Prepare the machine for charging suspension cylinders:

Park the machine on level ground. Turn off engine

Verify that the body is completely empty of material

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Verify that the machine is clean (no heavy mud loading)

Verify that the body is lowered

Verify that the fuel tank is full

Fully grease all suspension cylinder, cylinder pin, and A frame service points
2. Identify suspension cylinders to be charged
Note: Suspension cylinder charging is done in pairs, either both rear suspension cylinders or
both front suspension cylinders. If both front and rear suspension cylinders need to be charged,
gauge blocks should be used. Position the gauge blocks front suspension cylinders while the
rear suspension cylinders are charged first.

One or both rear suspension cylinder needs charging – Charge both rear suspension
cylinders

One or both front suspension cylinder needs charging – Charge both front suspension
cylinders

At least one front and at least one rear suspension cylinder needs charging – Charge all
four suspension cylinders

"Truck Payload Measurement System" (TPMS) accuracy has declined to an unacceptable

level – Charge all four suspension cylinders

Charge Front or Rear Suspension Cylinders

1. Front suspension cylinders - collapse. Completely evacuate all the nitrogen and oil from the
front suspension cylinders (For collapsed height, see Table 7 for front suspension cylinders).

2. Front suspension cylinders - charge with oil. Purge the front cylinders with fresh TDTO SAE
10W oil. Continue to purge the cylinders until oil is mostly free of bubbles. Charge the front
suspension cylinders to the specified oil charge height with CAT TDTO SAE 10W oil including
1U-9891 Hydraulic Oil Additive mixed in with the oil.
Note: Mix at 189.4 mL (6.44 oz) of additive to 18.9 L (19.9 qt) of oil.

For best results charge both suspension cylinders at the same time to reduce imbalance
between the suspension cylinders. (Table 7 indicates charge height for front suspension
cylinders.

3. Front suspension cylinders - Set on gauge blocks. Adjust the nitrogen pressure
regulator to the regulator pressure called out in Table 6. Charge both front suspension cylinders
with nitrogen at the same time. Raise the suspension cylinders enough to insert the gauge
blocks. To avoid damaging the seal, be sure to insert the gauge blocks with chamfer towards

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the seal. The full gauge block length is used for the 777. The shorter, notched, length is used
for 769 to 775. Release enough nitrogen to lower the truck onto the gauge blocks.
4. Rear suspension cylinders – collapse. Completely evacuate all the nitrogen and oil
from the rear suspension cylinders (For collapsed height, see Table 7 for rear suspension
cylinders).

5. Rear suspension cylinders - Charge with oil. Purge the rear cylinders with fresh
TDTO SAE 10W oil. Continue to purge the cylinders until clean oil is emitted from each
cylinder. Charge the rear suspension cylinders to the specified oil charge height with CAT
TDTO SAE 10W oil including 1U-9891 Hydraulic Oil Additive mixed in with the oil. (Mix at
189.4 mL (6.44 oz) of additive to 18.9 L (19.9 qt) of oil. For best results charge both suspension
cylinders at the same time to reduce imbalance between the suspension cylinders. (Table7
indicates charge height for rear suspension cylinders).

6. Rear suspension cylinders - Charge with Nitrogen. Adjust the nitrogen pressure to
the regulator pressure called out in Table 7. Charge both rear suspension cylinders with
nitrogen at the same time. Stop charging when the cylinders are approximately 25 mm (1 inch)
below specified ride height. (Table 7 indicates ride height for rear suspension cylinders). The
ride height may continue to rise for several minutes. Once the cylinder has stabilized, add or
remove nitrogen to reach correct ride height.
Note: The suspension cylinder pressures may be different between each suspension cylinder

7. Front suspension cylinders - Add initial pressure and remove gauge blocks.
Add additional pressure to front suspension cylinders. Refer to Table 6 for initial pressure.
Raise the body and remove the gauge blocks from the front suspension cylinders. Lower the
body.

8. Front suspension cylinders - Charge with Nitrogen. Check ride height of front
suspension cylinders (Table 6 indicates ride height for front suspension cylinders). Adjust the
nitrogen pressure regulator to the regulator pressure called out in Table 6 . Charge both front
suspension cylinders with nitrogen at the same time. If one suspension cylinder reaches the
correct ride height before the other, stop the flow of nitrogen to that suspension cylinder.
Continue to add nitrogen to the other suspension cylinder until the cylinder reaches proper ride
height. (Note: the suspension cylinder pressures may be different between each suspension
cylinder).

9. Proceed to "Verification Check and Final Adjustments".

Charge all 4 Suspension Cylinders

1. Collapse suspension cylinders. Completely evacuate all the nitrogen and oil from the
suspension cylinders to be charged (For collapsed height, see Table 6 for front suspension

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cylinders. Table 7 for rear suspension cylinders, Note: If only one rear suspension cylinder
needs servicing, perform the procedure on both rear suspension cylinders). If only one front
suspension cylinder needs servicing, perform the procedure on both front suspension
cylinders).
2. Charge with oil. Purge the cylinders with fresh TDTO SAE 10W oil. Continue to purge the
cylinders until clean oil is emitted from each cylinder. Charge the suspension cylinders to
specified oil charge height with CAT TDTO SAE 10W oil including 1U-9891 Hydraulic Oil
Additive mixed in with the oil. (Mix at 189.4 mL (6.44 oz) of additive to 18.9 L (19.9 qt) of oil. For
best results charge both suspension cylinders at the same time to reduce imbalance between
the suspension cylinders. (Table 7 indicates charge height for rear suspension cylinders, Table
6 indicates charge height for front suspension cylinders).

3. Charge with nitrogen. Adjust the nitrogen pressure regulator to the regulator pressure
called out in Table 6 for the rear suspension cylinders, or in Table 7 for the front suspension
cylinders. Charge both rear suspension cylinders with nitrogen at the same time. Stop charging
when the cylinders are approximately 25 mm (1 inch) below specified ride height. (Table 6
indicates ride height for rear suspension cylinders, Table 7 indicates ride height for the front
suspension cylinders). The ride height may continue to rise for several minutes. Once the
cylinder has stabilized, add or remove nitrogen to reach correct ride height.
Note: The suspension cylinder pressures may be different between each suspension cylinder.

4. Proceed to "Verification Check and Final Adjustments".

Verification Check and Final Adjustments

1. Drive the machine for at least 10 minutes making several turns, stops, and starts to exercise
the suspension.

2. Allow the machine to roll smoothly and slowly to a stop on level ground. Recheck suspension
heights and adjust as necessary. If adjustments were necessary, repeat Step 1 and Step 2.

3. Perform the payload calibration as instructed. It is important to follow the procedure and allow
the machine to roll to a stop on smooth and level ground when the calibration procedure is
being performed.

Worksheets
Table 8
Model Of The Machine Date
Serial Number Service Meter Hours
Component Damage

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Table 9
Rear Suspension Cylinders
Left Right
Oil Leaks
Nitrogen Leaks
Pin to Pin Dimension(1)
(1) This measurement is the dimension between the center of the top mounting pin to the center of the lower mounting pin.

Table 10
Front Suspension Cylinders
Left Right
Oil Leaks
Nitrogen Leaks
Length of Chrome
Length of Clean Chrome

Table 11
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).

Date:___________________________

Technician:______________________

PIP-11179035
2023/08/17
20:20:24-04:00
i03546660
© 2023 Caterpillar Inc.

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