794 AC Off-Highway Truck Machine Systems Caterpillar

Assembly Procedure

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In order to prevent possible personal injury, use a suitable fixture to support the weight of the suspension cylinder. Do not attempt to stand the suspension cylinder on end without the use of a suitable support. Failure to use a suitable support fixture could result in injury or death to personnel in this area.

1. Support the rear suspension cylinder with a suitable fixture. The weight of the rear suspension cylinder is approximately 1023 kg (2255 lb).
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   Illustration 1	g06331274

2. Lubricate inside housing assembly (8) and outside of rod assembly (13) with fluid being sealed.
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   Illustration 2	g06331048

3. Apply Tooling (C) in grooves for wiper seal (18), O-ring seal (17), and buffer seal (16).

4. Install wiper seal (18), O-ring seal (17), and buffer seal (16).
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   Illustration 3	g06338242

5. Apply Tooling (C) to grooves for O-ring seals (14) and back-up rings (15).

6. Install back-up rings (15) and O-ring seals (14) on head (9).
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   Illustration 4	g06331011

   Note: Support head (9) after installing to keep from falling.

7. Use a suitable lifting device to install head (9). The weight of head (9) is approximately 77 kg (170 lb).
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   Illustration 5	g06331010

   Note: Apply a small amount of Tooling (B) to balls (12) to keep balls in place.

8. Install balls (12) into bores of rod assembly (13).
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   Illustration 6	g06330997

9. Use a suitable lifting device to install head (11). The weight of head (11) is approximately 36 kg (79 lb).
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   Illustration 7	g06330994

10. Install two bolts (10) 180 degrees apart. Tighten both bolts to a torque of 407 N·m (300 lb ft).

11. Install two bolts (10) 180 degrees apart and 90 degrees from the first two bolts installed. Tighten both bolts to a torque of 407 N·m (300 lb ft).

12. Install remaining bolts (10). Tighten bolts to a torque of 407 N·m (300 lb ft).

13. Tighten bolts (10) to a final torque of 515 N·m (380 lb ft).
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    Illustration 8	g06330979

14. Use Tooling (A) and a suitable lifting device to housing assembly (8). The weight of the housing assembly (8) is approximately 480 kg (1058 lb).

15. Install the housing assembly (8) onto head (9).
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    Illustration 9	g06330944

16. Install two bolts (7) 180 degrees apart. Tighten both bolts to a torque of 407 N·m (300 lb ft).

17. Install two bolts (7) 180 degrees apart and 90 degrees from the first two bolts installed. Tighten both bolts to a torque of 407 N·m (300 lb ft).

18. Install remaining bolts (7). Tighten bolts to a torque of 407 N·m (300 lb ft).

19. Tighten bolts (7) to a final torque of 515 N·m (380 lb ft).
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    Illustration 10	g06330939

20. Install bellow (6).

    Note: For rear suspension cylinders with zipper bellows, follow the following steps for installation.

    1. Unzip new bellow cover.

    2. Place bellow around chrome suspension rod (large end upward).

    3. Zip bellow up around chrome rod.

    4. Pull bellow up to fully seat large diameter end of the bellow around the suspension lower bearing/packing gland.

    5. Remove the nylon locknut and spring from the large T-bolt clamp to open.

    6. Place large T-bolt clamp around bellow at the approximate center of upper bellow clamping area and around the lower bearing/packing gland.

    7. Connect clamp ends and reinstall the spring and nylon locknut.

    8. Torque the locknut to 7 N·m (65 lb in).

    9. Push the lower bellow clamping area up the chrome rod until the bellow accordions are straight and in a mostly closed position.

    10. Remove nylon locknut and spring from small T-bolt clamp to open.

    11. Place small T-bolt clamp around bellow at the approximate center of lower bellow clamping area and around the chrome rod.

    12. Connect clamp ends and reinstall the spring and nylon locknut.

    13. Torque the locknut to 7 N·m (65 lb in).
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    Illustration 11	g06330893

21. Install charging valve (4) and plug (5).
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    Illustration 12	g06330888

22. Install valve guard (3) and bolts (2).
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    Illustration 13	g06331398

23. Use Tooling (A) and a suitable lifting device to rotate the rear suspension cylinder in a vertical position. Support the rear suspension cylinder with a suitable fixture. The weight of the rear suspension cylinder is approximately 1023 kg (2255 lb).

24. Fill cylinder with oil as outlined in Testing and Adjusting, UENR2267, Rear Suspension (Cylinder) - Purge and Charge.
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    Illustration 14	g06331406

25. Install plug (1).

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1. Install the rear suspension cylinder.