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 vehicle must be empty and on a level surface. Use tooling (A) as a support under the vehicle frame as shown.
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To prevent personal injury do not stand under the vehicle when it is lifted or lowered. The clearance above your head can decrease suddenly. |
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2. Use tool (D) to release nitrogen from the suspension cylinder.
3. Lower the weight of the vehicle with tooling (A) on the cylinder until the rod is completely retracted. Remove tool (D).
4. Remove the tire and rim. See REMOVE FRONT TIRE AND RIM.
Earlier
Later
5. Disconnect brake line (1) from the fitting on the back of the brake.
6. Fasten a hoist to the steering cylinder as shown. Remove four bolts (3) that fasten steering arm (4) to spindle (2). Move the steering arm toward the rear of the vehicle.
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To prevent possible injury the following procedure to remove bolts (6) must be followed. Use of any other method can cause the bolts to break. |
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7. Fasten a hoist to the spindle and brake assembly. Loosen each bolt (6) one half turn at a time in sequence. Remove the bolts, plate (5) and shims from the bottom of the suspension cylinder.
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8. Install tooling (B) on the spindle as shown. Use tooling (B) to loosen the suspension cylinder rod taper from the bore in the spindle. Remove the tooling. Remove tooling (B) and remove the spindle and brake assembly. The weight of the spindle and brake assembly is 1000 lb. (454 kg).
9. Remove all bolts and nuts (7) but two that fasten suspension cylinder (8) to the chassis.
10. Install tooling (C) on the suspension cylinder as shown. Fasten tooling (C) to a lift truck. Remove the last two bolts and nuts (7) and remove the suspension cylinder and key. The weight of the suspension cylinder is 750 lb. (340 kg).
Install Front Suspension Cylinders
1. Install tooling (B) on suspension cylinder (2) and lift the cylinder into position on the chassis. Install two bolts and nuts (1) that fasten the top of the cylinder to the chassis. Use tool (C) as shown to pull the bottom of the cylinder into position. Install key (3) and the remainder of bolts and nuts (1). Remove tooling (B) and (C).
2. Put 2P2506 Anti-Seize Compound on the taper of suspension cylinder rod (4). Fasten a hoist to spindle (5) and brake assembly. Put the spindle in position on the suspension cylinder rod.
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3. Measure the thickness of plate (6).
4. Install plate (6) on the suspension cylinder rod with two bolts (7) 180° apart. Tighten the bolts to a torque of 100 ± 15 lb.ft. (135 ± 20 N·m).
NOTE: A measurement with a depth micrometer can be made. Be sure to keep the depth micrometer as close to the side of the bolt hole in the retainer as possible. Make sure the depth micrometer does not go into the threaded hole in the suspension cylinder.
5. Measure the distance between the bottom of the plate and the bottom of the cylinder rod through one of the bolt holes with a depth micrometer. This measurement minus the thickness of the plate (measured in Step 3) is the gap between the top of the plate and the bottom of the cylinder rod.
6. The gap between the top of the retainer plate and the bottom of the cylinder rod minus .075 ± .001 in. (1.91 ± 0.03 mm) is the correct thickness of shims.
NOTE: The thickness of the shims must not be less than .025 in. (0.64 mm).
7. Remove the bolts and plate. Install the correct thickness of shims, the plate and the bolts. Install the shims and tighten the bolts that hold the retainer to a torque of 500 ± 25 lb.ft. (680 ± 35 N·m).
8. Fasten a hoist to the steering cylinder and move steering arm (9) into position on the spindle. Install four bolts (8) that fasten the arm to the spindle.
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9. Install O-ring seal (11) on brake line fitting (10). Install the brake line. Remove the air from (bleed) the brake system. See TESTING AND ADJUSTING.
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end by:
a) install front tire and rim
b) charge front suspension cylinders (oil)
c) charge front suspension cylinders (nitrogen)
Disassemble Front Suspension Cylinders
start by:
a) remove front suspension cylinders
1. Put the cylinder in position on tooling (A) as shown.
2. Remove ball check valve (3) from the head.
3. Remove bolts (2). Remove cover assembly (1).
4. Remove bolts (4) and washers that hold the head to the cylinder housing.
5. Install two 1/2"-13 NC guide pins (6) (180° apart) in the cylinder housing. Remove head (5).
6. Remove O-ring seal and back-up ring (7) from the head.
7. Remove nuts (8) that hold the piston (9) to the rod.
8. Fasten tool (B) to the piston with two 1/2"-13 NC bolts 1" long. Put tool (B) in position on tooling (A) as shown. Use tooling (A) to remove the piston from the rod.
9. Remove the piston from tool (B). Remove wear ring (10) from the piston.
10. Fasten tool (B) to the rod with four 1/2"-13 NC nuts. Use tooling (A) to remove the tube (11), gland and rod assembly part way from the housing assembly.
11. Put support (13) in position under the rod as shown. Remove housing assembly (12) from the rod. Fasten a hoist to the housing assembly. Remove the housing assembly from tooling (A). The weight of the housing assembly is 420 lb. (189 kg).
12. Remove wiper (14), seal (15) and wear ring (16) from the cylinder housing.
13. Put tooling (A) in position on the tube as shown. Use tooling (A) to remove the tube and gland part of the way from rod (17). Remove the ball from the rod.
14. Put support (13) under the rod as shown. Remove gland (18) and tube (19) from the rod with tooling (A). Fasten a hoist to the tube. Remove the tube from tooling (A). The weight of the tube is 80 lb. (36 kg).
15. Remove O-ring seal and back-up ring (20) from the gland. Remove seal (21).
Assemble Front Suspension Cylinders
1. Install seal (2) in the bore of the gland. Install back-up ring and O-ring seal (1). Put a small amount of clean SAE 10 oil on the seals.
2. Install gland (3) in the tube.
3. Install wear ring (4), seal (5) and wiper (6) in the housing assembly.
4. Fasten a hoist to the housing assembly. Put housing assembly (7) in position on tooling (A) as shown.
5. Fasten a hoist to the tube. Install the gland and tube (8) in the housing assembly.
6. Install tool (B) on the rod with four 1/2"-13 NC nuts. Fasten a hoist to the rod. Put rod (9) in position on tooling (A) and support (10).
7. Use tooling (A) to install the rod part of the way in the the housing assembly. Remove tool (B) from the rod.
8. Install ring (11) on the piston.
9. Install ball (13) in the rod. Install piston (12) on the rod.
NOTE: Do not install the nuts that hold the piston to the rod at this time.
10. Install tool (B) on the piston with two 1/2"-13 NC bolts 1" long. Put tool (B) in position on tooling (A). Use tooling (A) to install the rod and piston in the housing assembly.
11. Remove tool (B) from the piston and tooling (A). Install the nuts that hold the piston to the rod.
12. Install backup ring and O-ring seal (14) on the head. Put a small amount of SAE 10 oil on the O-ring seal and backup ring.
13. Install two 1/2"-13 NC guide pins (16) in the housing assembly. Install head (15) on the housing assembly. Make sure the tapped hole (17) for the ball check valve is parallel to the flange of the housing assembly. Install the bolts that hold the head to the housing assembly, but do not tighten the bolts even finger tight while the housing assembly is in a horizontal position.
14. Tighten the bolts as follows.
a) Put the housing assembly in a vertical position.
b) Tighten four equally-spaced bolts in an "X" pattern to a torque of 50 N·m (37 lb.ft.).
c) Tighten all the bolts around the circle to a torque of 100 ± 15 N·m (75 ± 11 lb.ft.).
d) Repeat strap (C) until there is no change in the torque.
15. Install ball check valve (19) in the head.
16. Install the O-ring seal in the cover assembly. Install cover assembly (18) on the head.
17. Fill lower section of the suspension cylinder at lubrication fitting (20) with 5P960 Multipurpose Type Grease.
end by:
a) install front suspension cylinders
Charge Front Suspension Cylinders (Oil)
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To prevent personal injury do not check the oil in the suspension cylinder until all of the nitrogen pressure has been released. Do not, under any conditions, remove valves or plugs from the cylinder unless the rod is fully retracted and all nitrogen pressure is released. Add oil only when the suspension cylinder rod is fully retracted and all nitrogen pressure has been released. Do not stand under the vehicle when it is lifted or lowered. The clearance above your head can decrease suddenly. |
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1. To remove the nitrogen pressure in the suspension cylinders, the vehicle must be empty and on level ground. Use tooling (A) as support for the front of the truck.
2. Install the nitrogen charging chuck, tool (B) on the nitrogen valve (1). Turn the chuck clockwise to open the nitrogen valve. Use tooling (A) to lower the frame until the cylinders are completely retracted.
NOTE: The rod is completely retracted when the distance between the bottom of the cylinder housing and the top of the spindle is .53 in. (13.5 mm).
3. Remove plug (3) and open ball check valve (2).
4. Install tooling (B) and (C) on valve (1).
NOTE: Use only SAE 10W oil in the suspension cylinders.
5. Use tooling (C) to put oil in the suspension cylinder until the oil flow from the vent hole on top of the suspension cylinder is constant and free of air. Close the ball check valve (2). Turn the nitrogen charging check on the nitrogen charging valve (1) COUNTERCLOCKWISE to close the valve. Remove tooling (B) and (C).
end by:
a) charge front suspension cylinders (nitrogen)
Charge Front Suspension Cylinders (Nitrogen)
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Dry nitrogen is the only gas approved for use in the suspension cylinders. The charging of oxygen gas in these components, by accident, will cause an explosion. This danger can be done away with by the use of nitrogen cylinders with standard CGA (Compressed Gas Association, Inc.) No. 580 Connections. When nitrogen gas is ordered, make sure to order the cylinders with CGA No. 580 Connections. Do not go by color codes or other methods of identification to tell the difference between nitrogen and oxygen cylinders. In any application 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. |
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NOTE: The recommendation is to always charge the suspension cylinders in pairs.
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To prevent personal injury do not stand under the vehicle when it is lifted or lowered. The clearance can decrease suddenly. |
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1. Charge the cylinders with oil. See CHANGE FRONT SUSPENSION CYLINDERS (Oil).
2. Turn both charging chucks (1) all the way COUNTERCLOCKWISE.
3. Close shutoff valve (2).
4. Connect nitrogen charging equipment as illustrated.
5. Turn charging chuck (1) all the way CLOCKWISE to open nitrogen charging valve.
6. OPEN valve (3) on the nitrogen tank and adjust the regulator until line pressure gauge (4) gives an indication of approximately 500 psi (3450 kPa).
7. OPEN the individual cylinder valves (5) and the shutoff valve (2) slowly. Charge the cylinders until the chrome rod is extended to dimension (A).
8. CLOSE shutoff valve (2) and valve on nitrogen tank.
9. Turn charging chuck (1) all the way COUNTERCLOCKWISE.
10. When rod dimensions are correct, remove the charging equipment.
EARLIER MACHINE SHOWN
NOTE: Reference dimension (A) can be used to fast check the fully charged condition of cylinders. The dimension is 6.00 to 6.50 in. (15.2 to 16.5 cm).