KENR8377

October 2009

Specifications
797F Off-Highway Truck
Suspension Cylinder
LAJ1-Up (Machine)

SAFETY.CAT.COM
 i03684547

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels
on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must
not use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that the product will not be damaged or become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
KENR8377 3
Table of Contents

Table of Contents
Specifications Section
Suspension Cylinder (Front) ................................. 4
Pressure Sensor (Front Suspension Cylinder) ..... 6
Suspension Cylinder (Rear) .................................. 6
Pressure Sensor (Rear Suspension Cylinder) ...... 9
Valve (Suspension Cylinder Charging) ................. 9

Index Section
Index ..................................................................... 10
4 KENR8377
Specifications Section

Specifications Section (7) Apply a bead of 8T-0065 Silicone Sealant to the

surface that is surrounding the 5 tapped holes at
the machined face of the spindle.
i03626643
(8) Thickness of the shim pack ....... 6 mm (0.2 inch)
Suspension Cylinder (Front)
SMCS Code: 7201
Part No.: 292-2171 Personal injury or death can result when working
with the strut rod.

Sudden release of the spindle from the strut rod

or the snapping of a bolt when removing the plate
can result in injury.

Loosen all bolts one-half turn, working around the

plate in a circular pattern. Perform this again and
again until the torque is released for the bolts.

(9) Torque for 12 bolts ..................... 3100 ± 350 N·m

(2286 ± 258 lb ft)

g01945015
Illustration 1

Note: If the front suspension cylinder is disassembled,

reassemble the cylinder only in the vertical position.

Note: Refer to Specification, “Valve (Suspension

Cylinder Charging)” for specifications on the valve
assembly (1).

(2) Before installation to the bore, lubricate the

O-ring seal and the poppet of the block.

(3) Lubricate the taper of the strut rod with a coat g01945462
of 4C-5592 Anti-Seize Compound prior to Illustration 2
assembly to the axle. View A-A

(4) Before assembly, clean the rim mounting surface (10) The rubber toric seals and all surfaces that
of the front wheel. The rim mounting surface of contact the toric seals must be clean and dry at
the front wheel must be free of paint and grease. assembly. Apply a thin film of oil to the contacting
surfaces of the metal seal rings before you
(5) Apply 4C-4030 Thread Lock Compound to the assemble the rings.
threads of 12 bolts.
(11) Apply 4C-4030 Thread Lock Compound to the
(6) Apply a coat of 1U-8801 Rust Preventive Oil to threads of the pipe plug.
the machined face of the spindle.
KENR8377 5
Specifications Section

Note: Apply 154-9731 Thread Lock Compound

to the threads of the bolts (12) after adjusting the
bearing assembly.

(12) Torque for 10 bolts ................... 1800 ± 200 N·m

(1328 ± 148 lb ft)

Note: Apply 154-9731 Thread Lock Compound to

the threads of the bolts (13).

(13) Torque for six bolts .. 20 ± 3 N·m (177 ± 27 lb in)

g01945437
Illustration 3

g01945022
(14) Before assembly, lubricate the threads of the Illustration 4
bolt with 4C-5592 Anti-Seize Compound.
(15) Before assembly of head, fill the upper cavity
with 118 mL (4 oz) of 9X-2037 Additive.

(C) Outside diameter of piston .... 465.66 ± 0.13 mm

(18.333 ± 0.005 inch)

(D) Inside diameter of tube .... 466.75 to 466.87 mm

(18.376 to 18.381 inch)

(E) Outside diameter of rod ..... 399.975 ± 0.050 mm

(15.7470 ± 0.0020 inch)

(F) Bore diameter of the gland over three

lands ... 400.43 ± 0.03 mm (15.765 ± 0.001 inch)

(16) Fill the lower cavity with 6.25 L (1.65 US gal) of

clean grease after assembly.

(17) Apply 154-9731 Thread Lock Compound to

the bolt. Hand tighten the bolt. The end should
not turn when the bolt is tightened.

(18) Before assembly, apply 4C-4032 Bearing

Mount Compound to the wiper seal groove.
6 KENR8377
Specifications Section

i03629298 i03091775

Pressure Sensor (Front Suspension Cylinder (Rear)

Suspension Cylinder) SMCS Code: 7201; 7213
SMCS Code: 1408 Part No.: 289-8618
Part No.: 221-3417

g01946664
Illustration 5

(1) Final installation torque for the pressure sensor

group ............................. 45 ± 5 N·m (33 ± 4 lb ft)
g01573114
Supply voltage ....................................... 8 to 32 VDC Illustration 6

Frequency range ..................... 200.00 to 1602.56 Hz (1) Install the bearings so that the separation line
(fracture plane) is in alignment with the horizontal
Operating temperature ........................ −40 to 110 °C centerline of the bearing.
(−40 to 230 °F)
The inside diameter of the bearings
Note: The pressure sensor group may be installed 90 ............ 171.45 + 0 − .025 mm (6.75 + 0 − .001 inch)
degrees in either directions from the vertical position.
The port of the pressure sensor group should be (2) Prior to assembly, lubricate four pins with
pointed in the downward direction. 4C-5592 Anti-Seize Lubricant .

(3) Wrap the Cover (2) around the housing. Position

the seam toward the centerline of the truck.

(4) 5M-6214 Plug is on the bottom of each rear

suspension cylinder. Assemble the grease line
to the hole that is positioned toward the axle
housing. Plug the outboard hole.
KENR8377 7
Specifications Section

g01573133
Illustration 7
View A-A

g01573273 g01573274
Illustration 8 Illustration 9
View B-B View C-C

(5) Reference Illustration 8 for the location of the (5) Reference Illustration 9 for the location of the
lube holes lube holes
8 KENR8377
Specifications Section

g01573277
Illustration 10
View D-D

(6) Main valve 178 mm (7/8 inch)

Torque for main valve body .......... 13.6 ± .5 N·m
(120 ± 4 lb in)

g01573313
Illustration 11
Suspension Group

Note: See Testing And Adjusting, SEHS 9411,

“Servicing the Suspension Cylinders for Off-Highway
Trucks” for the charging procedure.

(1) Install the bearings so that the separation line

(fracture plane) is in alignment with the horizontal
centerline of the bearing.

The inside diameter of the

bearings ............................... 171.450 + 0 − .025 mm
(6.7500 + 0 − .001 inch)

(7) Diameter of rod assembly .. 381.08 + .15 − 0 mm

(15.0031 + .006 − 0 inch)

(8) Bore of cylinder assembly ........... 425.5 ± .1 mm

(16.75 ± 0.004 inch)

(9) Diameter of rod assembly ........ 418.82 ± .03 mm

(16.489 ± 0.001 inch)

(10) Lubricate the sealing lip slightly with the

lubricant that is being sealed.
KENR8377 9
Specifications Section

i03630965 i03091369

Pressure Sensor (Rear Valve (Suspension Cylinder

Suspension Cylinder) Charging)
SMCS Code: 1408 SMCS Code: 7201
Part No.: 221-3416 Part No.: 238-9928

g01947762
Illustration 12

(1) Final installation torque for the pressure sensor

group ............................. 45 ± 5 N·m (33 ± 4 lb ft)

Supply voltage ....................................... 8 to 32 VDC

g01502974
Illustration 13
Frequency range ..................... 200.00 to 1602.56 Hz

Operating temperature ........................ −40 to 110 °C (1) Torque for the valve cap ................... 4.5 ± 1 N·m
(−40 to 230 °F) (40 ± 9 lb in)

Note: The pressure sensor group may be installed 90 (2) Torque for the hex of the main body of the
degrees in either direction from the vertical position. valve ......................... 14 ± 3 N·m (125 ± 25 lb in)
The port of the pressure sensor group should be
pointed in the downward direction.
10 KENR8377
Index Section

Index
I

Important Safety Information ................................. 2

Pressure Sensor (Front Suspension Cylinder) ...... 6

Pressure Sensor (Rear Suspension Cylinder)....... 9

Specifications Section ........................................... 4

Suspension Cylinder (Front).................................. 4
Suspension Cylinder (Rear) .................................. 6

Table of Contents................................................... 3

Valve (Suspension Cylinder Charging).................. 9

KENR8377 11
Index Section
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