28/7/2021 SIS 2.

2018/11/27 Suspension Cylinder (Front) - Purge and Charge (RENR5126)

SMCS - 7201 i07583195

Perform Testing and Adjusting, "Visual Inspection" before you service the suspension cylinders.

The machine must be on level ground when you inspect the suspension cylinder charge. The truck body must be empty. Coast the machine to a
gentle stop without using the brakes. Apply the parking brake. Check the dimensions of the front suspension from the top of the wheel rim to the
top of the fender on both sides of the machine. Compare these dimensions to the dimensions that were recorded previously. The suspension
height will be different for each machine.

Note: Both suspension cylinders must be charged at the same time. If only one suspension cylinder needs servicing, perform the procedure on
both suspension cylinders.

Oil Requirements (Suspension Cylinder)

When you rebuild a suspension cylinder or when you assemble a suspension cylinder, use TDTO 10 W oil in the quantity that is specific to the
machine. Refer to Table 1.

Oil Quantities For Suspension Cylinders 

Model  Qty 
725  4 L (1.0567 US gal) 
730

4 L (1.0567 US gal) 
730 Ejector 
735  3.92 L (1.0355 US gal) 
740

3.92 L (1.0355 US gal) 

740 Ejector 

Table 1

Note: When you are charging the suspension cylinder with oil, use TDTO 10 W oil and add 1U-9891 Hydraulic Oil Additive. The ratio of additive to
oil is 12.5 ml per 1 L (0.2642 US gal).

After the suspension cylinder contains the required amount of oil, install the suspension cylinder. After this has been done, normal charging
procedures can be performed.

Charging Valves (Type 1 and Type 2)

Illustration 1 g06370616
Suspension cylinder with Type 1 charging valve
If the machine is installed with Type 1 charging valves, use 7S-5106 Chucks on the charging valves in the following procedures.

Illustration 2 g06370613
Suspension cylinder with Type 2 charging valve

If the machine is installed with Type 2 charging valves, use 1S-8938 Chucks on the charging valves in the following procedures.

Type 2 chucks incorporate an additional valve which must be opened and closed by rotating nut (A). To open the charging valve, perform the
following procedure:

1. Ensure that all charging equipment is fully closed.

2. Install the chuck onto the charging valve.

3. Rotate nut (A) counterclockwise in order to open the additional valve.

4. Turn the check valve on the chuck clockwise in order to open the charging valve.

To close the charging valve, perform the following procedure:

1. Turn the check valve on the chuck counterclockwise in order to close the charging valve.

2. Rotate nut (A) clockwise in order to close the additional valve. Tighten the nut to 7 ± 1 N·m (5 ± 0.7 lb ft).

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3. Remove the chuck from the charging valve.

Charging Tools

Illustration 3 g00295778
9U-5617 Oil Refill Pump
(1) Shutoff valve for the regulator

(2) 7S-5106 Chuck

(3) Shutoff valve

(4) Charging hoses

Note: Replace chucks (2) with 1S-8938 Chucks if the machine is installed with Type 2 charging valves.

Illustration 4 g00831850
175-5507 Nitrogen Charging Group
(5) 162-4147 Hose As

(6) 8S-4600 Fitting

(7) 8S-1506 Coupling

(8) 162-4146 Regulator

(9) 1S-8938 Chuck

(10) 7S-5106 Chuck

(11) 8T-0859 Pressure Gauge

(12) 8S-4599 Coupling

(13) 2S-5244 Fitting

(14) 1S-8937 Needle Valve

(15) 2D-7325 Pipe Tee

(16) 1S-8941 Hose As

Note: Chuck (10) is required for Type 1 charging valves. Chuck (9) is required for Type 2 charging valves.

Illustration 5 g00833037
175-7410 Nitrogen Charging Fitting Gp
(17) 8S-7169 Coupling

(18) 1S-8941 Hose As

(19) 7S-5106 Chuck

(20) 175-6857 Hose As

(21) 2D-7325 Pipe Tee

(22) 1S-8937 Needle Valve

(23) 5P-8998 Fitting

(24) 3D-8884 Elbow

Note: Replace chuck (19) with a 1S-8938 Chuck if the machine is installed with Type 2 charging valves.

Lowering the Suspension

Required Tools 

Tool  Part Number  Part Description  Qty 

1S-8937  Needle Valve  1 
175-6857 Hose As  1 
A  8S-7169 Coupling  1 
1S-8941 Hose As  1 
7S-5106 (1) Chuck  1 
B  1S-8938(2)  Chuck  1 

Table 2
(1)
(2) Type 1 charging valves
Type 2 charging valves

Note: Tooling (A) in Table 2 is part of the 175-7410 Nitrogen Charging Fitting Gp. Refer to Charging Tools.

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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.

When the suspension is lowered clearances between the

machine frames and suspension components are reduced.

Persons on or near the machine could be injured by crushing.

Keep all personnel clear of the machine until the suspension

has been lowered.

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.

Illustration 6 g00995672
Typical example
(1) Port (O)

( 2) Port (N)

( 3) Side Port

1. Remove the cover which protects the charging valves at port (1) and port (2). Remove the valve cap from the charging valve in port (2) that is
located on top side of the suspension cylinders. Before installing Tooling (A), turn the check valve on the chuck counterclockwise in order to
ensure that the charging valve will not open during installation. Make sure that the needle valve on the opposite end is fully closed. Install
Tooling (A) with the chuck on the charging valve and the needle valve into a suitable approved container.

2. Turn the check valve on the chuck clockwise. This opens up the charging valve. Move away from the machine before moving to the next step.

3. Open the needle valve and allow the nitrogen to flow through the charging valve into the suitable container. When the suspension cylinder
has bottomed completely, leave the check valve and the needle valve in position for five minutes in order to allow the pressure in the
suspension cylinder to equalize.

Purge and Charging the Suspension Cylinder

Required Tools 

Tool  Part Number  Part Description  Qty 

A  1S-8937  Needle Valve  1 
175-6857 Hose As  1 
8S-7169 Coupling  1 
1S-8941 Hose As  1 

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7S-5106(1) Chuck  1 
B  9U-5617  Oil Refill Pump  1 
C  175-5507  Nitrogen Charging Group  1 
D  1S-8938(2)  Chuck  1 

Table 3
(1)
(2) Type 1 charging valves
Type 2 charging valves

Note: Tooling (A) in Table 3 is part of the 175-7410 Nitrogen Charging Fitting Gp. Refer to Charging Tools.

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.

When the suspension is lowered clearances between the

machine frames and suspension components are reduced.

Persons on or near the machine could be injured by crushing.

Keep all personnel clear of the machine until the suspension

has been lowered.

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.

Illustration 7 g00995672
Typical example
(1) Port (O)

( 2) Port (N)

( 3) Side Port

1. Remove the valve cap from the charging valve in port (3) that is located on the suspension cylinder toward the rear of the machine. Before
installing Tool (A), turn the check valve on the chuck counterclockwise in order to ensure that the charging valve will not open during
installation. Make sure that the needle valve on the opposite end is fully closed. Install Tooling (A) with the chuck on the charging valve and
insert the needle valve into a suitable approved container.

2. Turn the check valve on the chuck clockwise. This opens up the charging valve. Move away from the machine before moving to the next step.

3. Open the needle valve and allow oil and nitrogen to flow through the charging valves into the suitable container. When the suspension
cylinder has bottomed completely, leave the check valve and the needle valve in position for five minutes in order to allow the pressure in the
suspension cylinder to equalize.
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28/7/2021 SIS 2.0

4. Remove the cover which protects the charging valves at port (1) and port (2) (not shown). Remove the valve cap from the charging valve in
port (1) and attach Tooling (B).

5. Use Tooling (B) in order to inject oil into the suspension cylinder. The oil will flow through the suspension cylinder then out of the charging
valve in port (3) and Tooling (A) into a suitable container. When the oil that is flowing out of the suspension cylinder is clean and free of air
stop Tooling (B) and turn the check valve on the chuck of Tooling (A) at port (3) counterclockwise. This will close the charging valve. Remove
Tooling (A).

6. Remove the valve cap from the charging valve in port (2) that is located on top side of the suspension cylinder. Before installing Tooling (A),
turn the check valve on the chuck counterclockwise in order to ensure that the charging valve will not open during installation. Make sure that
the needle valve on the opposite end is fully closed. Install Tooling (A) with the chuck on the charging valve and the needle valve into a
suitable approved container.

7. Turn the check valve on the chuck clockwise. This opens up the charging valve. Open the needle valve into the suitable container.

8. Use Tooling (B) in order to inject oil into the suspension cylinder. The oil will flow through the suspension cylinder then out of the charging
valve in port (2) and Tooling (A) into a suitable container. When the oil that is flowing out of the suspension cylinder is clean and free of air
stop Tooling (B) and turn the check valve on the chuck of Tooling (A) at port (2) counterclockwise. This will close the charging valve. Remove
Tooling (A) and Tooling (B).

9. Remove the valve cap from the charging valve in port (1) that is located on the top side of the suspension cylinder. Before installing Tool (A),
turn the check valve on the chuck counterclockwise in order to ensure that the charging valve will not open during installation. Make sure that
the needle valve on the opposite end is fully closed. Install Tooling (A) with the chuck on the charging valve and the needle valve into a
suitable approved container.

10. Turn the check valve on the chuck clockwise. This opens up the charging valve. Open the needle valve into the suitable container.

11. Install Tooling (C) onto the charging valve at port (2).

12. On the nitrogen cylinder, adjust the regulated pressure to 6895 kPa (1000 psi).

13. Open the needle valve on Tooling (C) and allow nitrogen to flow through the chuck which is connected to the charging valve at port (2). Turn
the check valve on the chuck clockwise. This allows nitrogen to flow through the charging valve and into the suspension cylinder. A small
amount of oil will flow out of Tooling (A) and into the suitable container.

14. When the flow of oil stops and only nitrogen is flowing through Tooling (A), turn the check valve on the chuck at port (2) counterclockwise on
Tooling (C). This will close the charging valve in order to stop the flow of nitrogen. Remove Tooling (C). Turn the check valve on the chuck at
port (1) counterclockwise before removing Tooling (A).

Nitrogen Charging Procedure (Setting the Suspension Ride Height)

Required Tools 

Tool  Part Number  Part Description  Qty 

C  175-5507  Nitrogen Charging Group  1 
D  175-7410  Nitrogen Charging Fitting Gp  1 
E  1S-8938(1)  Chuck  1 

Table 4
(1)
Type 2 charging valves

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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Illustration 8 g01041196

1. Measure Dimension (A) on both sides of the machine. Dimension (A) is the distance from the top of the rim to the bottom of the fender.
Dimension (A) will be different for each side of the machine. Record this number for both sides of the machine.

Illustration 9 g00995672
Typical example
(1) Port (O)

( 2) Port (N)

( 3) Side Port

2. Remove the cover which protects the charging valves at port (1) and port (2) (not shown) on both suspension cylinders. Remove the valve
cap from the charging valve in port (2) that is located on top side of each suspension cylinder. Before installing Tooling (C) and Tooling (D),
turn the check valves on the chucks counterclockwise in order to ensure that the charging valves will not open during installation. Make sure
that the needle valves on the opposite ends are fully closed.

3. On the nitrogen cylinder, adjust the regulated pressure to 6900 kPa (1000 psi).

4. Open the main needle valve. Open the needle valve which is in the line to the suspension cylinder on the left side. Turn the check valve on
the left side chuck clockwise. This opens up the charging valve in order to allow nitrogen to flow into the suspension cylinder. Allow the
suspension to raise the machine approximately 10 mm (0.40 inch) and then close the needle valve for the left side.

5. Open the needle valve which is in the line to the suspension cylinder on the right side. Turn the check valve on the right side chuck clockwise.
This opens up the charging valve in order to allow nitrogen to flow into the suspension cylinder. Allow the suspension to raise the machine
approximately 10 mm (0.40 inch) and then close the needle valve for the right side.

6. Alternate between the needle valve for the left side and the needle valve for the right side in order to allow the suspension to rise in
increments of 10 mm (0.40 inch) until the correct suspension ride height is achieved. The correct suspension height is Dimension (A) plus
Dimension (B). Refer to Step 1 and Table 5.
Suspension Height is Dimension (A) Plus Dimension (B). 

Model  Dimensions (B) 

725  105 ± 10 mm (4.15 ± 0.4 inch) 
730

105 ± 10 mm (4.15 ± 0.4 inch) 

730 Ejector 
735  75 ± 10 mm (3 ± 0.4 inch) 
740

75 ± 10 mm (3 ± 0.4 inch) 
740 Ejector 

Table 5

7. Operate the machine for several load cycles after the suspension has been properly charged. Recheck the ride height of the suspension. If
necessary, adjust the height of the suspension.

PPI-00077C9C
2021/07/28
18:44:54-04:00
i01911213
© 2021 Caterpillar Inc.
Caterpillar:
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