PSP-0002C766 2023/ 01/28 02:35: 02+08: 00 REH S4445 © 2023 Ca Terpi Llar Inc - Caterpi Llar: Confi Dentia L Gre en

Servicing the Suspension Cylinders for Off-Highway Trucks {0756, 7200, 7201, 7201, 7201, 7213, 7213}
2022/07/06
(REHS4445-20)
SMCS - 0756, 7200, 7201, 7213 i08989606

Off-Highway Truck/Tractor
PSP
769D (S/N: BBB1-UP; 5TR1-UP; 5SS1-UP)
770 (S/N: BZZ1-UP)
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770G (S/N: KD21-UP; KDH1-UP; ECM1-UP; ECX1-UP)
772 (S/N: RLB1-UP)
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772G (S/N: KE31-UP; LTS1-UP; KEX1-UP; LTX1-UP)
773D (S/N: NBJ1-UP; 7ER1-UP; 7CS1-UP)
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773E (S/N: BDA1-UP; PRB1-UP; KEG1-UP; ASK1-UP; DJS1-UP)
773F (S/N: EED1-UP; EXD1-UP)
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776C (S/N: 2TK1-UP)
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777 (S/N: 7M21-UP; 7W21-UP; 7M31-UP; 7W31-UP; 7M41-UP; 7W41-UP; 7M61-UP; 7W61-UP; 7W81-UP; 7W91-UP)
777C (S/N: 4XJ1-UP)
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777D (S/N: AGC1-UP; FKR1-UP; 3PR1-UP)
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Cat
777E (S/N: KYD1-UP; KZD1-UP; KDP1-UP; KDZ1-UP)
777F (S/N: JRP1-UP; JXP1-UP)
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777G (S/N: T5A1-UP; TNM1-UP; RDR1-UP; T4Y1-UP)
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Quarry Truck
771D (S/N: BCA1-UP; 6JR1-UP; 6YS1-UP)
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773G (S/N: MWH1-UP; JWS1-UP; T5S1-UP; T5T1-UP)
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775D (S/N: 6KR1-UP; 8AS1-UP)
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775E (S/N: BEC1-UP)
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775F (S/N: EYG1-UP; DLS1-UP)
775G (S/N: T5F1-UP; RFM1-UP; MJS1-UP; T5W1-UP)
Revision History:
Revision History
Revision Summary of Changes
20 Added new 777 serial number prefixes.
19 "KYD" and "KZD" prefix added.
18 Added video link and QR code.
Significant Revision.
17 Reworked Table 6.
Significant procedure and step adjustments.
Table 1
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
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Improved shock absorption and operator comfort
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Higher suspension cylinder reliability
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Improved ability to maintain the intended level of controllability
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Better operating efficiency
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Increased accuracy of the payload measurement system
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Note: These procedures are to maintain the correct suspension cylinder charge and the correct ride height.
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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
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Cat
175-7410 Auxiliary Fitting Group"
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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
Safety Information PSP

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The following information is an explanation of various labels that are found in this document.
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Warnings
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The warning label informs the technician that an injury or death can occur as a result of a condition that may exist.
Notices
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A notice informs the technician that component damage can occur as a result of a condition that exists.
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Notes
A note contains general information for the technician about the operation that is being performed.
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Proper repair is important to the safe operation and the reliable operation of this machine. This document outlines recommended
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procedures. Some of the procedures require special tools, devices, or work methods.
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Before you perform any repairs or before you perform any maintenance, read all safety information. Understand all safety
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information before you perform any repairs or before you perform any maintenance.
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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.
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The “Safety Alert Symbol” that is followed by a “Signal Word” identifies a hazard. “DANGER”, “WARNING”, and “CAUTION”
are “Signal Words”.
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The signal word “WARNING” has the following meanings:
Pay Attention !
Become Alert !
Your Safety Is Involved !
The message that appears under the safety alert symbol explains the hazard.
Operations or conditions that may cause product damage are identified by "NOTICE" labels on the machine and in the service
information.
The person that services the machine may be unfamiliar with many of the systems on the machine. Use caution when you perform
service work. Special knowledge of the systems and of the components is important. Before you remove any component or
before you disassemble any component, obtain knowledge of the system and knowledge of the component.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in
this document and the safety information on the machine are not all inclusive. You must determine that the tools,
procedures, work methods, and operating techniques are safe. You must determine that the operation, lubrication,
maintenance, and repair procedures will not damage the machine. Also, you must determine that the operation,
lubrication, maintenance, and repair procedures will not make the machine unsafe.
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.
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Read all warning labels on the suspension cylinders before
servicing. Do not check the oil in the suspension cylinder until all
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the nitrogen pressure has been released.
Do not, under any condition, remove valves, cover or plugs from
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the cylinder unless the rod is fully retracted and all the nitrogen
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pressure is released.
Do not stand under the machine when testing or adjusting the
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suspension cylinders.
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Personal injury or death can result from improper lifting or
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When a hoist or jack is used to lift any part or component, stand
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clear of the area. Be sure the hoist or jack has the correct
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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
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surfaces where parts are to be installed.
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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
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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
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machine on the ground, the machine may suddenly move due to
internal sticking of the suspension cylinders.
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NOTICE
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Care must be taken to ensure that fluids are contained during
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performance of inspection, maintenance, testing, adjusting, and
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repair of the product. Be prepared to collect the fluid with
suitable containers before opening any compartment or
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disassembling any component containing fluids.
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Refer to Special Publication, PERJ1017, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain
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fluids on Cat® products.
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Dispose of all fluids according to local regulations and mandates.
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Always observe the list of basic precautions that follows:
Safety Signs
Safety signs include the items that follow: signs, information plates, and decals. Read all “Safety” signs on the machine before
operating, lubricating, or repairing the machine. Understand all “Safety” signs on the machine before operating, lubricating, or
repairing the machine. Replace any safety signs that are in the conditions that follow: damage, unreadable and missing.
Protective Equipment
When you work around the machine, always wear protective equipment that is required by the job conditions. Protective
equipment includes the items that follow: hard hat, protective glasses, and protective shoes. In particular, wear protective glasses
when you use a hammer or when you use a sledge hammer. When you weld, use the appropriate protective equipment that is
required by the job conditions. Protective equipment for welding includes the items that follow: gloves, welding hood, goggles,
and apron. Do not wear loose clothing or jewelry that can catch on parts of the machine.
Mounting and Dismounting

Use steps and hand holds whenever you mount the machine. Use steps and hand holds whenever you dismount the machine.
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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
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with the step and with hand holds.
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Note: Three-points contact must be used when mounting or dismounting the machine.
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Do not mount a moving machine. Do not dismount a moving machine. Never jump off the machine. Do not try to mount the
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machine when you carry tools or supplies. Do not try to dismount the machine when you are carrying tools or supplies. Use a
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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
EH and0Lifting
RChains,
the cab.
Specifications for Cables, 2+0Devices

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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
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critical. Refer to the Illustration that follows to see the effect of the lift angle on the working load limit.
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Note: The lifting devices that are shown in this publication are not Caterpillar parts.
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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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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.
Pressurized Items
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1. Always use a board or a piece of cardboard when you check for a leak. Leaking fluid under pressure can penetrate body
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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.
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2. Relieve all pressure in nitrogen, oil, or water systems before any lines, fittings, or related items are disconnected or removed.
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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.
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3. Fuel lines that are damaged and fuel lines that are loose can cause fires. Lubrication lines that are damaged and lubrication
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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
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your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.
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4. Pressure nitrogen or water can cause personal injury. When pressure nitrogen or water is used for cleaning, wear a protective
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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
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frequently above 13790 kPa (2000 psi). Follow all the recommended practices that are provided by the manufacturer of the
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pressure washer.
Definitions
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Carry or On the Ground Pressure - The Carry Pressure is the pressure seen in the suspension cylinders when the truck is on level
ground
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Ride Height - The Ride Height is used as a target value for charging the suspension cylinders. The Ride Height for each
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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.
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
Required Oil
Cat TDTO SAE 10W(1)
Cat HYDO Advanced 10 SAE 10W(2)
Table 2
(1)
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(2) Cat TDTO with friction modifier is preferred
Cat HYDO is an acceptable substitute without friction modifier
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Friction Modifier Mixing Instructions (99% Suspension Oil, 1% Friction
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Friction Modifier
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Modifier)
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Part Number Suspension Oil Friction Modifier
3.78 L (1 US gal) 37.89 mL (1.28 oz)

1U-9891 Hydraulic Oil Additive
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(1 qt container of 100% Friction 18.9 L (5 US gal) 189.4 mL (6.4 oz)
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Modifier)
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208 L (55 US gal) 2083.8 mL (70.4 oz)
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Note: Friction modifier must be mixed to the suspension oil before the suspension cylinders are charged with oil.
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Required Tools Ca
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Item Qty Part Number Description
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A 1 9U-5617 Oil Refill Pump(1)
B 1
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175-5507 Nitrogen Charging Group(1)
C 1
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175-7410 Nitrogen Charging Fitting Gp(1)
D 1
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7F-8240 Hand Tool (TIRE VALVE STEM REPAIR)
E
Table 4
2 FT1680
n Gauge Block(2)
(1)
(2) 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.
Fabricated
Reference: Special Instruction, NEHS0742  for assembly instructions for tool (B) and tool (C).
Required Parts
Item Qty Part Number Description

- 4 440-2668 Valve Core
Table 5
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
Tool 9U-5617 Oil Refill Pump (A)
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g00295778
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( 1) Shutoff valve for the regulator
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(2) 7S-5106 Chuck
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(2) 1S-8938 Chuck
(3) Shutoff valve
(4) Charging hoses
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Tool 175-5507 Nitrogen Charging Group (B)
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( 5) 162-4147 Hose As
(6) 8S-4600 Fitting
(7) 8S-1506 Coupling
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(8) 162-4146 Regulator
(2) 7S-5106 Chuck
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(2) 1S-8938 Chuck
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(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
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 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.
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.
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Check for leakage at the O-rings that are located under the manifold and under the pressure sensor. Check for leakage at the O-
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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.
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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
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Note: Use a ladder or appropriate device to reach the appropriate height to inspect the charging valves.
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Note: Friction between the rod and the lower wear band may cause a dark stain to appear on the chrome of the suspension
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cylinder. This stain does not affect the wear life of the suspension cylinder. The chrome can be polished to remove the stain.
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Eventually, the wear band should become soaked by oil and grease and the blackening should decrease.
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Charging Process Flowchart
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Illustration 10
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Identify Suspension Cylinders to be - 0
Charged
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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
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charged in pairs. The pairs consist of either both front or both rear suspension cylinders. In addition, if the "Truck Payload
2
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Measurement System" (TPMS ) accuracy has declined to an unacceptable level, it may be necessary to charge all 4 suspension
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cylinders.
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One or both rear suspension cylinders needs charging – Charge both rear suspension cylinders
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One or both front suspension cylinders needs charging - Charge both front suspension cylinders
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At least one front and at least one rear suspension cylinder needs charging – Charge all 4 suspension cylinders
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TPMS accuracy has declined to an unacceptable level – Charge all 4 suspension cylinders
a teSuspension CaCylinders
Procedure to Collapse
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Collapse the Suspension llar:
Cylinders to be illa
Charged
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Note: If the front suspension cylinders are being serviced, collapse both front suspension cylinders at the same time. If the rear
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suspension cylinders are being serviced, collapse both rear suspension cylinders at the same time.
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Note: The cylinders must be collapsed before the charge procedure is executed. The actual amount of oil in a cylinder cannot be
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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.
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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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Views of collapsing rear suspension cylinders with all valves open
(AA) Charging valve
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Typical view front suspension
(AA) Charging valve
(AB) Valve cap
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.
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Typical view
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2. Locate two chucks (2) that are part of the nitrogen charging group.
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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.
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Turn the tee handle counterclockwise on chucks (2) to ensure that the valve cores on the charging valves will not
open during installation.
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Typical view front suspension
(AA) Charging valve
Typical view rear suspension
(AA) Charging valve
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).
Use a wrench to hold charging valve (AA) and a second wrench to turn the swivel nut that is on charging valve (AA)
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counterclockwise to open charging valves (AA).
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Note: Opening charging valves (AA) allows oil and nitrogen to flow through the charging valves so that the suspension
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cylinders will collapse completely.
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5. Let oil and nitrogen flow into the suitable container until the suspension cylinders have collapsed.
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typical view of front cylinder
(BB) Exposed chrome length front suspension cylinder
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RE 02+
Illustration 19
HS 08:
g03784690
4
Typical view rear cylinders
©2 4 00
(B) Pin to pin dimension rear suspension cylinders
4
0 5
6. After the suspension cylinders have collapsed completely, leave the charging valves in the open position for 5 to 10 minutes
2 3C
Cat
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
erp ater
chrome height (BB) and compare to dimension given in Table 6. For the rear suspension cylinders, measuring the pin to pin
Con illa pill

dimension (B) and compare to dimension given in Table 7.
fide r: ar I
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Cat 23 C
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Con illa pill
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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.
ntia nc.
Also, turn the tee that is on chucks (2) counterclockwise to close the core valve on charging valves (AA).
Charge the Suspension Cylinders withl Oil

8. Proceed to Section "Charge the Suspension Cylinders with Oil".
G re
en
View of purging the front suspension cylinders of oil with all valves open
(A) 9U-5617 Oil Refill Pump
(AA) Charging valve
PSP
202 -0002
3/0 C76
02: 1 6
35: /28
RE 02+
HS 0
© 2 444 8:00
Illustrative view of purging the rear suspension cylinders of oil with all valves open
(AA) Charging valve
0 5
Cat 2 3C
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© 2 444 00
0 2 3C 5
Cat
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Typical view front suspension cylinder
(AA) Charging valve
(AB) Valve cap
Typical view rear suspension cylinder
(AA) Charging valve
(AB) Valve cap
PSP
202 0002-
3 C
02: 01/2 766
/
35: 8
RE 02+
HS 0
© 2 444 8:00
0 2 3C 5
Cat
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illa pil
EH +08
S
© 2 444 :00
0 2 3C 5
Cat
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(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.
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.
PSP
202 -0002
3 C
Illustration 25
Typical view
02: 01/2 766
/
g03775735
35: 8
RE 02+
3. Locate four chucks (2) that are part of the nitrogen charging group.
HS 08:
Install the charging hoses onto chucks (2).
©2 4 4 4 00
023 5
Cat
35:
RE 02+
HS 0
© 2 444 8:00
5
Note: Two of the charging hoses will be used to drain oil into an approved container. Two of the charging hoses will be used
Cat 0 2
to pump oil into the suspension cylinders.
3C
Turn the tee handle that is on chucks (2) counterclockwise to ensure that the charging valves will not open during
installation.
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(AA) Charging valve
(AB) Valve cap
Typical view of rear suspension cylinder
(AA) Charging valve
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).
PSP
8. Turn the tee handle on all four chucks (2) clockwise to open valve cores (AC).
202 -0002
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).
3/ C76
10. Begin to operate Tool (A) and pump oil into both suspension cylinders and out the drain hoses.
0
02: 1 6
Continue to pump oil into the suspension cylinders until the oil that comes from the drain hose on the outlet charging valve
35: /28
is mostly free of bubbles.
RE 02+
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.
HS 0
© 2 444 8:00
023 5
02: 01/2 66
35: 8
RE 02+
HS 0
© 2 444 8:00
0 2 3C 5
Cat
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View of charging the front suspension cylinders with oil
(AA) Charging valve
View of charging the rear suspension cylinders with oil
(AA) Charging valve
PSP
-
202 0002
3 C
02: 01/2 766
/
35: 8
RE 02+
HS 0
44 8:00
023 02C
02: /01/2 766
35: 8
RE 02+
HS 0
© 2 444 8:00
0 2 3C 5
Cat
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Illustration 30
Typical view of front suspension cylinder
(BB) Exposed chrome length
n
g06484471
Typical view rear suspension cylinder
(B) Pin to pin dimension
PSP
12. On both outlet line chucks, turn the tee handle (2) counter clockwise to close valve cores (AC). Remove discharge line
202 -0002
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
3 C76
0.5 ± 0.1 N·m (4.42 ± 0.88 lb in). Reinstall both inlet chucks (2).
/0
02: 1 6
35: /28
02+
0
P-0
202 002
3 C
02: 01/2 766
/
14. Start tool (A) and pump oil into each suspension cylinder to increase the cylinder height to the oil charged dimension shown
35: 8
in Table 6 for the front suspension cylinders and 7 for the rear suspension cylinders
RE 02+
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.
HS 0
© 2 444 8:00
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.
0 2 5
16. If charging both front suspension cylinders or both rear suspension cylinders, proceed to section "Charge Suspension
3C
Cat
Cylinders with Nitrogen"
erp ater
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"
Con illa pill

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

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View of front suspension cylinders
(AA) Charging valve
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).
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.

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. 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 12 mm
(0.5 inch) below ride height, turn the tee on chucks (2) counterclockwise to close valve cores (AC). The suspension cylinders
will continue to rise for a few minutes. Insert the gauge blocks with chamfer towards the seal to avoid damaging the seal. If
necessary add more nitrogen to insert the gauge blocks.
PSP
Note: The full gauge block length is used for the 777. The shorter, notched, length is used for 769 to 775.
6. Turn the tee handle that is on chucks (2) clockwise to depress the core valve on charging valves (AA). Use a wrench to hold
202 -0002
charging valve (AA) and a second wrench to turn the swivel nut that is on charging valve (AA) counterclockwise to open
charging valves (AA).
3/0 C76
1/2 6
8
PSP
202 -0002
3 C76
When the suspension cylinders are supported by the gauge blocks, use a wrench to hold charging valve (AA) and a second
/0
02: 1
wrench to turn the swivel nut that is on charging valve (AA) clockwise to close charging valves (AA). Do not overtighten the
35: /28 6
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.
RE 02+
HS 0
© 2 444 8:00
7. Remove tool (B) from the charging valves.
8. Perform "Procedure to Collapse Suspension Cylinders" on rear suspension cylinders.
0
Procedure to Remove Gauge
2
Blocks
3C 5
Cat
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View of front suspension cylinders
(AA) Charging valve
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.
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.
(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 (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.
PSP
9. Proceed to"Charge Suspension Cylinders with Nitrogen"to apply final nitrogen charge to the front suspension cylinders .
-
202 0002
3/0 C76
1 6
PSP
202 0002 -
Charge Suspension Cylinders with Nitrogen
3 /0 C76
02: 1 6
35: /28
RE 02+
HS 0
© 2 444 8:00
0 2 3C 5
Cat
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Illustration 34
fide r:
View of front suspension cylinders ar I
g06558368
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(AA) Charging valve
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Illustrative view of charging the rear suspension cylinders with nitrogen with all valves open
(AA) Charging valve
(AA) Charging valve
PSP
-00
02
(AB) Valve cap
PSP
202 0002-
3 C
02: 01/2 766
/
35: 8
RE 02+
HS 0
Illustration 37
© 2 444 8:00 g03782392
0 5
Typical view
2
(AA) Charging valve
Cat
3C
erp ater
1. If chucks (2) were removed, install one chuck (2) onto a charging valve (AA) on both of the suspension cylinders.
Con illa pill

fide r: ar I
2. Attach Tool (B) and the charging hoses to chucks (2).
nc.
3. Close all the valves on tooling (B). Turn the tees on chucks (2) counterclockwise, and swivel nuts (AD) clockwise on the
charging valves.
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4. Adjust the pressure on the regulator. Refer to table 6 for the regulator pressure when charging the front suspension
ree
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
n
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.
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)
(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.
PSP
202 -0002
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.
3 C76
8. After the correct right height is reached, close the valves on tooling (B), turn the tee on chucks (2) counterclockwise to close
/0
02: 1
valve cores (AC), and turn swivel nut (AD) clockwise on the charging valve to stop the flow of nitrogen.
35: /28
9. Remove tool (B) from the charging valves. 6
10. Check for leaks.
RE 02+
HS 0
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
© 2 444 8:00
(22.12 ± 4.42 lb in).
0 5
12. If charging all suspension cylinders and front suspension cylinders have not been changed with Nitrogen, proceed to
2 3C
Procedure to add initial nitrogen charge in the suspension cylinders supported by on gauge blocks.
Cat
If charging only rear suspension cylinders , proceed to "Verification Check and Final Adjustments".
erp ater
If charging front suspension cylinders , proceed to "Verification Check and Final Adjustments".
Conand FinalilAdjustments
Verification Check la pill
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1. After the suspension cylinders are charged, drive the machine for at least 10 minutes on a route that includes both left and
ntia
right turns. Bring the machine to a smooth gradual stop on level ground, without using the brakes or retarder.
lG
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.
ree
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Typical view
(BB) Exposed chrome length measurement
PSP
202 0002-
3 /0 C76
02: 1 6
35: /28
RE 02+
HS 0
© 2 444 8:00
0 2 3C 5
Cat
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Con illa pill
fide r: ar I
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Illustration 39 ntia g03784710
Typical view
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(B) Pin to pin dimension
n
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 being performed.
Front Suspension Cylinder Charging Specifications
Collapsed Chrome Oil Charged Chrome Ride Height Chrome Length Regulator Pressure
Model Oil Volume
Length(1) Length (Ground) Setting(2)
14 L
769 20 mm (0.79 inch) 45.4 mm (1.79 inch) 170 ± 13 mm (6.7 ± 0.5 inch) 2755 kPa (400 psi)
(3.7 US gal)(3)
14 L
(3.7 US gal)(3)
12 L
(3.2 US gal)(4)
12 L
(3.2 US gal)(4)
12 L
(3.2 US gal)(4)
12 L
(4)
775 (3.2 US gal)(4) 21 mm (0.83 inch) 46.4 mm (1.83 inch) 170 ± 13 mm (6.7 ± 0.5 inch) 4480 kPa (650 psi)
29 L
(7.6 US gal)(5)
29 L
PSP
(7.6 US gal)(5)
Table 6
(1)
(2)
Approximate
202 0002-
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
3 C
(3)
the pressure needed to raise the turck to ride height. If the truck does not rise with this pressure, slowly increase the pressure until the truck starts to rise.
02: 01/2 766

/
(4) 140 mL (4.76 oz) Friction Modifier required
(5)
120 mL (4.08 oz) Friction Modifier required
35: 8
02+
Rear Suspension Cylinder Charging Specifications
RE
Collapsed Pin to Pin Oil Charged Pin to Pin Ride Height Pin to Pin Regulator Pressure
Model Oil Volume
HS 0
© 2 444 8:00
Length(1) Length (Ground) Setting(2)
12 L 910 ± 13 mm
769 776 mm (30.50 inch) 801 mm (31.50 inch) 1725 kPa (250 psi)
5
(3.2 US gal)(3) (35.8 ± 0.5 inch)
771
12 L
(3.2 US gal)(3)
Cat 0 2 3C
776 mm (30.50 inch) 801 mm (31.50 inch)
910 ± 13 mm
(35.8 ± 0.5 inch)
1725 kPa (250 psi)
770
9L
erp ater
681 mm (27 inch) 706 mm (28 inch)
780 ± 13 mm
1725 kPa (250 psi)
Con illa pill

(2.4 US gal)(4) (30.7 ± 0.5 inch)
fide r:
9L 780 ± 13 mm
772
(2.4 US gal)(4)
681 mm (27 inch)
ar I 706 mm (28 inch)
(30.7 ± 0.5 inch)
1725 kPa (250 psi)
773
12 L
(3.2 US gal)(3)
ntia
887 mm (35 inch)
nc. 912 mm (36 inch)
1015 ± 13 mm
(40 ± 0.5 inch)
2415 kPa (350 psi)
775
12 L
lG
887 mm (35 inch) 912 mm (36 inch)
1015 ± 13 mm
2415 kPa (350 psi)
ree
(3.2 US gal)(3) (40 ± 0.5 inch)
n
16 L 1030 ± 13 mm
776 915 mm (36 inch) 928 mm (36.5 inch) 2415 kPa (350 psi)
(4.2 US gal)(5) (40.5 ± 0.5 inch)
16 L 1030 ± 13 mm
777 915 mm (36 inch) 928 mm (36.5 inch) 2415 kPa (350 psi)
(4.2 US gal)(5) (40.5 ± 0.5 inch)
Table 7
(1)
(2)
Approximate
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
(3)
the pressure needed to raise the turck to ride height. If the truck does not rise with this pressure, slowly increase the pressure until the truck starts to rise.
(4)
(5)
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
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
PSP
blocks front suspension cylinders while the rear suspension cylinders are charged first.
202 -0002
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
3 / C76
At least one front and at least one rear suspension cylinder needs charging – Charge all four suspension cylinders
0
02: 1 /2 6
"Truck Payload Measurement System" (TPMS) accuracy has declined to an unacceptable level – Charge all
3 5
four suspension cylinders
: 8
RE
Charge Front or Rear Suspension 02+
Cylinders
HS 0
© 2 444 8:00
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).
0 2 5
2. Front suspension cylinders - charge with oil. Purge the front cylinders with fresh TDTO SAE 10W oil. Continue to purge
3C
Cat
the cylinders until oil is mostly free of bubbles. Charge the front suspension cylinders to the specified oil charge height with
erp ater
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.
Con illa pill

For best results charge both suspension cylinders at the same time to reduce imbalance between the suspension
fide r: ar I
cylinders. (Table 7 indicates charge height for front suspension cylinders.
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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
lG
enough to insert the gauge blocks. To avoid damaging the seal, be sure to insert the gauge blocks with chamfer towards the
ree
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.
n
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 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
PSP
cylinder needs servicing, perform the procedure on both front suspension cylinders).
-
202 0002
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
3/ C76
results charge both suspension cylinders at the same time to reduce imbalance between the suspension cylinders. (Table 7
0
02: 1 6
indicates charge height for rear suspension cylinders, Table 6 indicates charge height for front suspension cylinders).
35: /28
3. Charge with nitrogen. Adjust the nitrogen pressure regulator to the regulator pressure called out in table 6 for the rear
RE 02+
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
HS 0
indicates ride height for rear suspension cylinders, table 7 indicates ride height for the front suspension cylinders.). The ride
© 2 444 8:00
height may continue to rise for several minutes. Once the cylinder has stabilized, add or remove nitrogen to reach correct
ride height.
0 5
Note: The suspension cylinder pressures may be different between each suspension cylinder.
2 3
C a Cat
4. Proceed to "Verification Check and Final Adjustments".
terpAdjustments
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Verification Check and Final
fide r:
1. Drive the machine for at least 10 minutes making several turns, stops, and starts to exercise the suspension.
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nc.
2. Allow the machine to roll smoothly and slowly to a stop on level ground. Recheck suspension heights and adjust as
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necessary. If adjustments were necessary, repeat Steps 1 and 2.
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3. Perform the payload calibration as instructed. It is important to follow the procedure and allow the machine to roll to a stop
ree
on smooth and level ground when the calibration procedure is being performed.
Worksheets
Model Of The Machine Date
n
Serial Number Service Meter Hours
Component Damage
Table 8
Rear Suspension Cylinders
Left Right
Oil Leaks
Nitrogen Leaks
Pin to Pin Dimension(1)
Table 9
(1)
This measurement is the dimension between the center of the top mounting pin to the center of the lower mounting pin.
Front Suspension Cylinders

Left Right
Oil Leaks
Nitrogen Leaks
Length of Chrome
Length of Clean Chrome
Table 10
Temperature Compensation
Temperature In The Service Shop
Outside temperature
PSP
-
Temperature Difference
202 0002
Added Length For Temperature Compensation(1)
Table 11
3 C
02: 01/2 766
/
(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:___________________________
35: 8
Technician:______________________
RE 02+
HS 0
PSP-0002C766
© 2 444 8:00
5
2023/01/28
02:34:34+08:00
i03546660
Cat 0 2 3C
erp ater
© 2023 Caterpillar Inc.
Caterpillar:
Confidential Green
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fide r: ar I
nc.
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ree
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PSP-0002C766 2023/ 01/28 02:35: 02+08: 00 REH S4445 © 2023 Ca Terpi Llar Inc - Caterpi Llar: Confi Dentia L Gre en

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Servicing the Suspension Cylinders for Off-Highway Trucks {0756, 7200, 7201, 7201, 7201, 7213, 7213}

SMCS - 0756, 7200, 7201, 7213 i08989606

772 (S/N: RLB1-UP)

Revision Summary of Changes

20 Added new 777 serial number prefixes.

19 "KYD" and "KZD" prefix added.

18 Added video link and QR code.

Better machine ride

Improved structural durability

Safety Information PSP

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The signal word “WARNING” has the following meanings:

Your Safety Is Involved !

Personal injury or death can result from sudden suspension

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

Do not, under any condition, remove valves, cover or plugs from

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Do not stand under the machine when testing or adjusting the

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Do not operate or perform any lubrication, maintenance or

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

Suspension groups should only be serviced by properly trained

Never use an adapter to connect your nitrogen charging group

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Mounting and Dismounting

Specifications for Cables, 2+0Devices

Hot Fluids and Parts

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Conditions for Servicing

Suspension cylinder shows signs of leakage.

Cat TDTO SAE 10W(1)

Cat HYDO Advanced 10 SAE 10W(2)

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

Item Qty Part Number Description

Fabrication of Charge Block (E)

Ensure that the fuel tank is full of fuel.

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Charge the Suspension Cylinders withl Oil

(2) 7S-5106 Chuck or 1S-8938 Chuck

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

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Procedure to Support Front

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

4. Adjust the pressure on the regulator. Refer to Table 6.

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

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

8. Lower the body.

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Temperature of the service shop ... 50° F

Difference in temperature ... (50° F) - (-40° F) = 90° F

Front Suspension Cylinder Charging Specifications

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Off-Highway Truck Suspension Charging Quick Reference Guide

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

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

Verify that the fuel tank is full

2. Identify suspension cylinders to be charged

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

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