FORK AS.- 1834797 - Caterpillar

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.Read all warning labels on the suspension cylinders before servicing. Do not check the oil in the suspension cylinder until all the nitrogen pressure has been released.Do not, under any condition, remove valves, cover or plugs from the cylinder unless the rod is fully retracted and all the nitrogen pressure is released.Do not stand under the machine when testing or adjusting the suspension cylinders.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Illustration 1 g00649232
Remove bolt (1) and the clip that holds wire harness (2) in position. Disconnect wire harness (2) at the electrical connection.
Remove four bolts (4) and the hard washers. Remove plate (3).
Illustration 2 g00649255
Remove four bolts (5) and the hard washers. Allow plate (6) to slide down the rear suspension cylinder.
Illustration 3 g00649257Note: To remove either of the rear suspension cylinders, the nitrogen in both rear suspension cylinders must be purged.
Remove the cap (not shown) and install Tooling (A) on the valves of both rear suspension cylinders. Purge the nitrogen from the rear suspension cylinders. Refer to Suspension Cylinder, System Operation, Testing and Adjusting, "Suspension Cylinder (Rear) - Purge and Charge" for the correct procedure.
Illustration 4 g06313112
Position Tooling (C) under the rear of the machine as shown. Use Tooling (C) to lift the frame assembly until the weight of the machine has been removed from the rear suspension cylinders. Refer to Tool Operating Manual, NEHS1328, "Lift Group (Stand - 60 Ton)" for more information on Tooling (C).
Illustration 5 g00702556
Remove two socket head bolts (7) and remove payload pressure sensor (8) from the rear suspension cylinder.
Illustration 6 g00649392
Remove four socket head bolts (10) and remove manifold (9) from the rear suspension cylinder.
Illustration 7 g00649262
Remove bolt (11), the full nut, and the three washers that hold upper pin (12) (not shown) in position.
Illustration 8 g00649266
Install body retaining pin (13) to keep rear suspension cylinder (14) in position while upper pin (12) is removed. Remove upper pin (12).
Position a suitable lifting sling around the rod end of rear suspension cylinder (14). Secure the suitable lifting sling to a hoist. Remove body retaining pin (13).
Illustration 9 g00649270
Lower the rod end of rear suspension cylinder (14) onto Tooling (D), as shown. Remove bolt (15), the full nut, and the three washers that hold lower pin (16) (not shown) in position.
Illustration 10 g00649271
Position a suitable lifting sling around the head end of rear suspension cylinder (14). Secure the suitable lifting sling to a hoist. Remove lower pin (16).
Remove rear suspension cylinder (14) from the machine. The weight of the rear suspension cylinder is 290 kg (640 lb).