SUSPENSION CYLINDER

DURING COMPRESSION
Service Training
MALAGA
777D Off Highway Truck
Adolfo
August 1997
VIII SUSPENSION.
1. Components Layout
2. Operation
3. Maintenance
4. Testing & Adjusting
CHAPTER : SUSPENSION
777D Off Highway Truck
VIII1 Page:
S
U
S
P
E
N
S
I
O
N

C
Y
L
I
N
D
E
R
D
U
R
I
N
G

C
O
M
P
R
E
S
S
I
O
N
CHAPTER : SUSPENSION
777D Off Highway Truck
VIII2 Page:
S
U
S
P
E
N
S
I
O
N

C
Y
L
I
N
D
E
R
D
U
R
I
N
G

E
X
T
E
N
S
I
O
N
C
H
A
P
T
E
R

:


S
U
S
P
E
N
S
I
O
N

7
7
7
D

O
f
f

H
i
g
h
w
a
y

T
r
u
c
k
V
I
I
I
3
P
a
g
e
:

CENTERED
EXTENDING
COMPRESSING
SUSPENSION CYLINDER
BALL CHECK VALVE AND ORIFICE OPERATION
ROD
HOUSING
C
H
A
P
T
E
R

:


S
U
S
P
E
N
S
I
O
N

7
7
7
D

O
f
f

H
i
g
h
w
a
y

T
r
u
c
k
V
I
I
I
4
P
a
g
e
:

GREASE
VALVE
GLAND
TUBE
PISTON
CHARGING
VALVE
BALL
CHECK VALVE
WEAR
RING
FRONT SUSPENSION
CYLINDER
CHARGING
VALVE
BALL
CHECK
VALVE
ORIFICE
REAR SUSPENSION
CYLINDER
ORIFICES
C
H
A
P
T
E
R

:


S
U
S
P
E
N
S
I
O
N

7
7
7
D

O
f
f

H
i
g
h
w
a
y

T
r
u
c
k
V
I
I
I
5
P
a
g
e
:

SUSPENSION GAS
VOLUME CHANGE UNDER PRESSURE
.095 LITER
(.1 QUART)
OF
NITROGEN
2050 kPa
(300 psi)
1.9 LITERS
(2.0 QUARTS)
LOW OIL
100 kPa
(15 psi)
CHAPTER : SUSPENSION
777D Off Highway Truck
VIII6 Page:
FRONT SUSPENSION CHARGING SEQUENCE:
Check for and eliminate any oil or nitrogen leaks.
Make sure the truck is empty and on level ground.
Put the open end of the suspension charging lines into an approved container. Open the charging valves
and allow the oil and nitrogen to drain from the suspension cylinders into the container.
Position a thin strip of sheet metal on both suspension cylinders. Place a piece of masking tape on the
sheet metal with the top edge of the tape even with the top of the spindle. Put a line across the
tape 12.7mm (0.50in) below the top edge of the tape.
Cycle some oil through the charging lines to fill them with clean oil.
Inject oil into the cylinders until each cylinder extends to the line made on the masking tapE.
To prevent oil flow from the suspension cylinders, adjust the nitrogen cylinder regulated pressure to
4150 kPa (600 psi). Charge the cylinders until the gauge blocks (and shims if required) can be
installed between the spindle and the cylinder housing.
Drain nitrogen from the suspension cylinders until the cylinder housings rest on the gauge blocks and
the regulated nitrogen pressure is less than 2400 kPa (350 psi).
Adjust the regulated nitrogen supply to 2400 kPa (350 psi). Open the charging valves and allow the
nitrogen to flow into the cylinders. Leave the valves open for approximately five minutes to
allow the nitrogen charge pressure to equalize in the two suspension cylinders.
Remove the nitrogen charging group from the suspension cylinders and install the charging valve caps.
Start the engine and raise the dump body to remove the gauge blocks.
CHAPTER : SUSPENSION
777D Off Highway Truck
VIII7 Page:
REAR SUSPENSION CHARGING SEQUENCE:
Check for and eliminate any oil or nitrogen leaks.
Make sure the truck is empty and on level ground.
Put the open end of the suspension charging lines into an approved container. Open the charging valves
and allow the oil and nitrogen to drain from the suspension cylinders into the container.
Position a thin strip of sheet metal on both suspension cylinders. Place a piece of masking tape on the
sheet metal strips with the top edge of the tape even with the top of the cylinder housing. Put
a line across the tape12.7 mm (0.5 in.) below the top edge of the tape. Place another piece of
masking tape on the sheet metal strips and make a line on the tape 101.6 mm (4 in.) below the
top of the cylinder housing. Put another line across the tape 114.3 mm (4.5 in.) below the top
of the cylinder housing (adjust the lower two dimensions for temperature if required).
Cycle some oil through the charging lines to fill them with clean oil.
Inject oil into the cylinders until each cylinder extends to the line made on the masking tape.
To prevent oil flow from the suspension cylinders, adjust the nitrogen cylinder regulated pressure to
2400 kPa (350 psi). Charge the cylinders with nitrogen until the top of the cylinder housing is
located within the two lines made on the lower piece of masking tape. Leave the valves open
for approximately five minutes to allow the nitrogen charge pressure to equalize in the two
suspension cylinders.
Remove the nitrogen charging group from the suspension cylinders and install the charging valve caps.
CHAPTER : SUSPENSION
777D Off Highway Truck
LAB EXERCISES
LAB B
FRONT SUSPENSION CYLINDER CHARGING WORKSHEET
Machine Model _______777D_______________Date_____________________________________
Serial Number ___________________________ Service Meter Hours________________________
Oil Charge Dimension ____________
Nitrogen Charge Dimension Temperature Correction:
Shop Temperature 10 C Outside Temperature -50 C Temperature Difference ________
Temperature Difference X = Shim Thickness ___________________
Corrected Nitrogen Charge Dimension _______________ Nitrogen Charge Pressure _____________
Chrome Length Measurement
After Gauge Block is Removed: * Left Front _____________ Right Front ____________
Wiped Chrome Dimension After Operation: Left Front _____________ Right Front ____________
* dimension between top of spindle and bottom of cylinder housing
SHIMS FOR TEMPERATURE CORRECTION
Shim Thickness
mm/5.5 C
Truck Model (in./10 F)
776D/777D 2.54mm(0.10in)
CHAPTER : SUSPENSION
777D Off Highway Truck
VIII9 Page:
POSTTEST
SUSPENSION SYSTEM POSTTEST
Directions: Modified True/False. If a question is false, underline or circle the word or words that make
the statement incorrect and replace with word(s) to make the statement correct.
Example: F 1. This is an engine class.
1. After the front suspension cylinders are charged with nitrogen and the gauge blocks are
removed, the exposed chrome length will usually be less than the gauge block dimension.
2. Before charging the suspension cylinders with nitrogen, the nitrogen charge hoses must be
pressurized to prevent high pressure oil in the cylinders from flowing into the nitrogen
charge hoses.
3. Always charge two suspension cylinders at the same time.
4. If the truck is in the shop and the temperature outside is 16 C (60 F) colder, the suspension
cylinder nitrogen charge length will be greater.
5. If the truck is in the shop and the temperature outside is 16 C (60 F) colder, the suspension
cylinder oil charge length will be greater.
6. Suspension cylinders will compress faster than they extend because of the ball check valve
located in the cylinder rod.
7. A blue/black patch of stain on the suspension cylinder chrome is caused by heat between the
rod and the wear band. The stain can be polished off and does not affect the wear life of the
suspension cylinder.
8. Greasing the front suspension cylinders too fast can cause the wiper seal to be forced out of
the bottom of the cylinder housing.