Usage:
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To prevent personal injury, do not under any condition, remove valves or plugs from the cylinder unless the rod is fully retracted and all nitrogen pressure is released. |
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1. The machine must be empty and on a level surface.
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To prevent personal injury, do not stand under the vehicle while it is being lifted or lowered. The clearance above your head can decrease suddenly. |
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2. Raise the side of the machine with a 50 ton screw jack far enough so that the front tire and spindle can be lowered off of the taper on the suspension cylinder when the cylinder is retracted.
3. Release all nitrogen pressure from the suspension cylinder. See Testing And Adjusting for the proper procedure.
4. Disconnect brake line (1). Plug the open fitting and brake line to prevent dirt entry.
5. Use tooling (A) to support the steering linkage assembly as shown. Remove four bolts (3), and move steering arm (4) away from wheel spindle (2) toward the rear of the vehicle. Remove tooling (A).
6. Put a lift truck in position under the tire and rim, and fasten the tire to it. The combined weight of the tire and rim, the wheel and brake assembly is approximately 1021 kg (2250 lb.).
7. Make sure that the suspension cylinder is fully retracted, and there is no nitrogen pressure in it.
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To prevent possible personal injury, do not loosen bolts (6) more than 1/2 turn at a time in any pattern other than a circular one. If any other method is used to loosen bolts (6), it may cause the bolts to break. |
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8. Loosen bolts (6) 1/2 turn at a time in a circular pattern until all the torque is removed from all the bolts. Remove the bolts, plate (5) and the shims.
9. Install tooling (B) as shown, and pull the spindle loose from the taper on the suspension cylinder.
10. Remove tooling (B). Remove the tire, wheel and brake assembly as a unit.
11. Use a 1 1/2" socket to remove bolt (7) and bolt (8) that hold the key in position. Remove the key.
12. The weight of the suspension cylinder is 310 kg (680 lb.). Position a lift truck to support the suspension cylinder, and attach tooling (A) as shown.
13. Remove the remainder of the mounting bolts except for two bolts (9).
14. Loosen two bolts (9) slowly, and adjust tooling (A) to keep the suspension cylinder vertical.
15. Remove two bolts (9), and remove the suspension cylinder.
Install Front Suspension Cylinders
1. Put the suspension cylinder into position on the frame with a lift truck and tooling (A) as shown. Install two bolts (1) to hold the suspension cylinder in place.
2. Install key (2) and two bolts (4) that hold it. Install the remainder of the bolts. Tighten all of the mounting bolts to a torque of 945 ± 34 N·m (695 ± 25 lb.ft.). Remove tooling (A) and the lift truck.
3. Inspect the tapered portion of rod (3). There should not be a lip or any other damage to the rod that would prevent it from properly seating into the spindle.
4. Put 2P2506 Thread Lubricant on the taper of the suspension cylinder rod.
5. Put the tire and rim, the wheel and brake assembly in position so the spindle is on the taper of the suspension cylinder rod.
6. Put plate (4) in position without any shims, and install two bolts (5) 180 ° apart as shown. Tighten the bolts evenly to a torque of 135 ± 20 N ·m (100± 15 lb.ft.).
7. Measure the distance between the bottom of plate (4) and the bottom of suspension cylinder rod (3) using the small hole provided. Make a note of this measurement.
8. Measure the thickness of plate (4). Make a note of this measurement.
9. Subtract the thickness of plate (4) measured in Step 8 from the distance measured in step 7. This value is the distance between the top surface of plate (4) and the bottom surface of cylinder rod (3).
10. Subtract 1.91 ± .03 mm (.075 ± .001 in.) from the distance between the top of plate (4) and the bottom of cylinder rod (3) found in Step 9. This valve will be the thickness of the shim pack required to go between the plate and the cylinder rod.
NOTE: The thickness of the shims must not be less than 0.64 mm (.025 in.).
11. Put the shim pack and plate (4) in position, and install four bolts (5). Tighten bolts (5) evenly to a torque of 675 ± 34 N·m (500 ± 25 lb.ft.). It will be necessary to torque the bolts several times before they will maintain the correct torque value.
NOTE: The gap between the plate and rod may be as much as 0.13 mm (.005 in.) after bolts (5) are tightened in Step 11.
12. Attach tooling (A) to put steering arm (8) in position on the spindle. Install four bolts (7). Remove tooling (A).
13. Connect brake line (6).
14. Lower the machine to the ground.
15. Charge the front suspension cylinders with oil and with nitrogen. See Testing And Adjusting for the proper procedure.
16. Remove (bleed) the air from the the brake system. See Remove Air From Hydraulic Brake System in Testing And Adjusting, Form SENR7814-02, for the proper procedure.
Disassemble Front Suspension Cylinders
START BY:
a. remove front suspension cylinders
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To prevent possible personal injury, the suspension cylinder must be completely discharged before it is disassembled. |
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1. Put the suspension cylinder in a vertical position on tooling (A), and install two bolts (2) to hold it in position.
2. Remove the three bolts that fasten cover (1) to the cylinder. Remove the cover and seal.
3. Remove two valve assemblies (4) from cylinder head (5).
4. Put alignment marks on head (5) and the cylinder housing. Remove 16 bolts (3), and remove head (5).
5. Remove the seal and back-up ring from head (5).
6. Drain the oil from the cylinder. To do this, slowly rotate the cylinder on the stand enough to pour the oil into a pan.
7. Remove the 10 nuts holding piston (6). Install tooling (B) into the threaded holes in the piston, and remove piston. Fasten a hoist to tooling (B), and remove the piston.
8. Remove ring (7) from piston (6).
9. Install tooling (C), tooling (D) and tooling (E) as shown. Lift rod assembly (8) from cylinder bore until ball check (9) is exposed. Remove the ball check.
10. Lift rod assembly (8) until it is free in the cylinder bore. Remove tooling (C).
11. The weight of cylinder rod assembly (8) is 93 kg (205 lb.).
12. Install tooling (F) into tooling (E) as shown. Attach a hoist to tooling (F), and remove the rod assembly.
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To prevent possible personal injury, tooling (D) should be in place. It will prevent the tube from falling out when the cylinder is rotated 180 °. |
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13. Rotate the cylinder 180° on the stand, and remove wiper (9), seal (11) and ring (10) from the bottom of the cylinder bore.
14. Rotate the cylinder 180° on the stand back to the upright position, and remove tooling (D).
15. The weight of the gland and tube (12) is 31 kg (68 lb.). Use tooling (G), and remove the tube and gland together as a unit.
16. When the tube and gland are free from the cylinder bore, attach a hoist to tooling (G), Remove tooling (G), tube (12) and the gland as a unit from the cylinder.
17. Remove tooling (G) from the tube and gland.
18. Separate gland (15) from tube (12).
19. Remove seal (13) and ring (14) from the outer diameter of gland.
20. Remove seal (16), seal (17) and ring (18) from the inner diameter of gland.
Assemble Front Suspension Cylinders
1. Put the suspension cylinder in a vertical position on tooling (A), and install two bolts to hold it.
2. Install yellow seal (6), black seal (5) and ring (1) into gland (4).
3. Install seal (2) and ring (3) onto the outer diameter of gland (4) as shown.
4. Put clean oil on all seals. Put gland (4) into the end of the tube. The gland and tube will be installed into the cylinder as an assembly.
5. Use 5P960 Multipurpose Grease to coat the entire outer surface of the tube to prevent corrosion buildup.
6. Weight of the gland and tube assembly is 31 kg (68 lb.). Attach tooling (B) to the gland and tube assembly (7). Attach a hoist to tooling (B), and lower the gland and tube assembly into the cylinder. Remove tooling (B).
7. Use tooling (C) to hold the tube in place. Rotate the cylinder 180 ° on stand.
8. Install ring (9), seal (10) and wiper (8) into the bottom of cylinder as shown.
9. Put clean oil on the ring, seal and wiper. Rotate the cylinder 180 ° on the stand back to the upright position.
10. Remove tooling (C).
11. The weight of cylinder rod assembly (11) is 93 kg (205 lb.). Attach tooling (D) and tooling (E) to the cylinder rod assembly. Attach a hoist to tooling (E). Put clean oil on the rod assembly, and lower it into the cylinder tube.
12. Remove tooling (E) from tooling (D).
13. Use tooling (D) and tooling (F) to push the rod assembly into the cylinder tube as shown.
14. Put ball check (12) in position in the rod assembly.
15. Remove tooling (F) and tooling (D).
16. Install ring (14) on piston (13). Put clean oil on the ring. Put the piston in position on the rod assembly, and use tooling (G) to push the piston and rod assembly into the cylinder tube. Remove tooling (G).
17. Install the 10 nuts that fasten the piston to the rod assembly. Tighten them to a torque of 90 ± 14 N·m (65 ± 10 lb.ft.).
NOTE: If the suspension cylinder rod is filled with SAE 10W oil now, it will result in a time savings when the cylinder is charged with oil after it is installed on the vehicle.
18. Install valve assemblies (15) and (16) into suspension cylinder head (19).
19. Install seal (17) on head (19) so that it will be toward the inside of the cylinder. Install back-up ring (18) on the head so that it will be toward the outside of cylinder after assembly.
20. Put clean oil on the ring and seal.
21. Put head (19) in position on the cylinder, and install the 16 bolts that hold it. Use the alignment marks for correct positioning of the charging valves.
22. Install the seal in cover assembly (20). Put the cover assembly in position, and install the three bolts that hold it.
23. Remove the suspension cylinder from tooling (A).
END BY:
a. install front suspension cylinder