Hitachi Construction Truck Manufacturing Ltd.

NEOCON SUSPENSION
STRUT CHARGING MANUAL

12/21/2006

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 Table of Contents
Hitachi Construction Truck Manufacturing Ltd.

Safety Instructions..........................................................................................................................1
Service Position ..............................................................................................................................2
Lifting Procedure ............................................................................................................................3
Strut Charging Procedure ..............................................................................................................5
Helium/Neocon Inflation Illustration..............................................................................................7
Strut Charging Data and Measurement.........................................................................................8
Strut Charging Specifications........................................................................................................9

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 Safety Instructions
Hitachi Construction Truck Manufacturing Ltd.

Safety Instructions
A FEW SIMPLE RULES WHEN PERFORMING STRUT CHARGING:

• Do not perform any work on the machine unless you are authorized to do so.

• Maintenance can be dangerous unless performed properly. Be satisfied that you have the
necessary skill, information, correct tools, and equipment to do the job correctly.

• Standard maintenance procedures should always be observed. Read the manufacturer’s

manual or find assistance if you do not understand what you are doing.

• Read all nameplates and decals before you operate the machine. Each nameplate and
decal has important information about operation or service.

• Do not wear loose fitting clothing or jewelry when working on a machine.

• Always wear a hard hat, safety glasses, gloves, shoes, and other protective articles as the
job requires.

• Before you work on the machine always lower the body. If you must work on the machine
with the body raised, always securely support the body using the body prop cable.

• Be sure the “Body Prop” Cable or Pins are connected when working beneath a raised dump
body.

• When lifting or supporting components, use equipment with a weight capacity as great as or
greater than the weight of the component.

• Use the correct tool(s) for the job. Repair or replace any broken or defective equipment or
tools.

• Make sure that no tool(s) or other object(s) are left inside the machine where they may
cause damage.

• Be sure the machine is in the SERVICE POSITION before lifting the machine. Always
support an elevated machine using proper blocks and/or cribbing before beginning work.

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Service Position

Note: Turn the steering wheel several times to remove residual steering pressure.
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Lifting Procedure
The following lifting/jacking procedures are to be used as guide lines and for reference only.
Weather, working conditions, expertise of service personnel, job location, and available equipment
will affect and possibly change these procedures. For specific instructions and lifting equipment
specifications, reference the LIFTING AND JACKING PROCEDURES (Section 7), in the service
literature provided with the truck you will be lifting.

Since the work environment dictates the type of lifting/jacking equipment needed for each situation,
the proper equipment must be chosen for your particular job. Examples of various lifting equipment
are: cables, slings, shackles, blocks, clevis, jacks and cranes.

• The machine must be empty prior to jacking or lifting for repairs.

• Lifting ports on the side of the dump body are to be used for lifting the dump body
ONLY, not the entire machine.

• Read and follow all cautions, warnings and instructions provided by the equipment
manufacturers of the lifting/jacking devices being used.

• Before working on the machine, park it on a level surface and put in the Service
Position. Refer to SAFETY INSTRUCTIONS / SERVICE POSITION.

• Always chock tire and wheel on the opposite side of the machine prior to positioning
the jack. Always crib/block the machine after jacking in the event the jack slips from
position.

• The jacking device must be placed on a level and firm surface.

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 Lift Eyelets, Front Frame Lift Eyelets, Rear Frame

Lifting, Cribbing/Blocking Front Frame Lifting, Cribbing/Blocking Rear Frame

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 Strut Charging Procedure
Hitachi Construction Truck Manufacturing Ltd.

Strut Charging Procedure

To maintain ride quality of the Neocon suspension, proper charging and adjustment procedures
must be followed in conjunction with the appropriate service literature.

Before beginning the charging procedure, ensure the truck is empty, parked on level ground in the
“service position”, with the park brake applied, the wheels properly blocked and enough cribbing to
allow the struts to rest at the X-4 dimension. An appropriate rated hoist is required to raise the truck
using the proper lifting method to fully extend the struts to the X-1 dimension during charging.

The charging procedures for the front and rear struts are the same. The best practice is to charge
the front struts first.

Special tooling required to complete the strut charging procedure:

• A tank of compressed helium gas with enough gas to complete charge procedure
• A liquid pump for filling the strut with Neocon-E fluid
• A charging kit, (special tool number E4082333), that contains a regulator valve and all the
lines and fittings needed to properly charge the struts.
• An optional Neocon filtration cart, (special tool number E12977832), that can filter the
recovered Neocon-E fluid for reuse.

It is very important that both struts on either the front or rear are charged simultaneously.

The strut charging procedure is the same when installing new struts, except new struts come
completely filled with Neocon-E fluid and all air has been bled at the factory. You can skip the liquid
fill procedure when installing new struts.

Liquid fill and Air Bleeding procedure:

• Using a ¾” wrench, crack open the inflation valve at the top of the struts to bleed off any
trapped pressure then continue opening by turning the lock-nut counterclockwise until hand
tight.
• Allow the struts to drain of compressed helium gas
• Remove liquid fill plug. On trucks equipped with Haultronic, remove the strut transducer and
one-way check valve assembly.
• Fully extend the struts to the X-1 dimension
• With the struts completely extended verify the X-1 dimension as specified in the service
literature
• Connect the liquid fill lines into the plug port on both struts using the “T” provided, allowing
both struts to be filled simultaneously.
• Ensure the inflation valves are open to bleed-off trapped air
• Attach hoses to the inflation valves and run to a clean container
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 • Begin filling the struts with Neocon-E fluid
• Continue filling the struts with Neocon-E fluid until the struts are completely full and the fluid
flowing out of the inflation valves into the container is free of air bubbles
• Close the inflation valves
• Disconnect the liquid fill line at the pump and place pump end in a clean container
• Lower the truck allowing the struts to collapse to the X-4 dimension as specified in the
service literature
• Remove all lines and fittings, replace plugs or strut transducer and one-way check valve
assemblies and torque to 31-34 ft.lbs

This completes the liquid fill procedure and the strut should now have the proper volume of liquid
with all internal cavities filled and free of air.

Now we can inflate the struts with helium gas.

Inflation Procedure:

• Adjust the helium gas pressure to 100 psi pre-charge using the regulator on the supply tank
• Connect the gas inflation lines to the inflation valves on both struts - but leave loose
• Open the charge kit valves on each line and purge the inflation lines with short bursts of
helium gas
• Tighten the inflation lines after purging with helium gas
• Check all connections for gas leakage. Listen for gas leakage closely or use glycerin
detergent and water solution on all connections to detect bubbles.
• Close the charge kit valves on each line
• Using a ¾” wrench, open the inflation valve at the top of the struts by turning the lock-nut
counterclockwise until hand tight.
• Open the charge kit valves on each line
• While maintaining the 100 psi pre-charge fully extend the struts to the X-1 dimension

DO NOT extend the struts without the 100 psi pre-charge as it is possible for air to enter the
strut and cause damage to internal components.

If there is a question as to the possibility of air entering the struts you must repeat the liquid
fill procedure.

• With the struts completely extended to X-1, inflate them simultaneously by adjusting the
regulator valve on the helium tank to the proper pressure as specified in the service
literature
• Once again check the X-1 dimension to ensure struts are fully extended
• After verifying the X-1, allow the helium pressure to normalize for approximately 1 minute.
Once the pressure has normalized, close the strut inflation valves to a torque of 100 in.lbs
• Close the supply valve on the helium tank

• Evacuate the gas inflation lines using the bleed valve located on the charging kit manifold
• Turn gas regulator to low value before storage of gas regulator.
• Disconnect the inflation lines and fittings

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 • Remove cribbing and lower the truck

The front struts are now charged with proper liquid and helium gas volume. Repeat procedure for
rear axle.

After the initial 48 hour operating period the strut should be checked at 50 hour intervals thereafter
to monitor the condition of the struts and to ensure the X-2 dimension is maintained between the
cylinder gland and the top of the rod assembly. This is accomplished with the truck empty and
parked on level ground. Prior to checking the X-2 dimension the truck should be operated for a
minimum of 1 hour.

Failure to follow the proper procedure may result in inaccurate readings.

This procedure in conjunction with the appropriate service literature will provide all the necessary
information to properly charge the Neocon suspension struts.

Helium/Neocon Inflation Illustration

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Strut Charging Data and Measurement

During the first 48 hours of operation the helium gas and the Neocon-E in the struts will mix in a
dissolution process. As dissolution occurs, the strut lengths will change and a reduction in the strut
height and inflation pressure is to be expected. After the initial 48 hour operating period, the struts
should be checked at regular intervals. To monitor the condition of the strut, there is only one
dimension to be checked. With the machine empty and parked on level ground measure the X-2
dimension, between the cylinder gland assembly and the top of the rod assembly.

DO NOT measure from the top of the rubber damper, (See illustration above).

Prior to checking the X-2 or P1-A, the machine should be operated a minimum of one hour and
rolled to a stop. Failure to follow these directions may result in false readings.

When the strut dimension is out of tolerance, check the following:

• Look for signs of Neocon--E leakage.

• Check the P1-A pressure with the strut fully extended to the X-1 dimension. Remedy any
apparent problem and proceed according to the charging procedure.
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Strut Charging Specifications

35 – 105 Ton

NEOCON SUSPENSION SPECIFICATIONS

PART X-2 X-4 NEOCON
MODEL AXLE X-1 P1 P1-A
NUMBER (Truck Empty) (Truck Empty) VOLUME*
FRONT 12570882 11.0 +/- 0.25" 8.0 +/- 1.0" 2.0 +/- 0.25" 775 +/- 5psi N/A 2.5 gal.
R35
REAR 12570880 6.0 +/- 0.25" 4.5 +/- 0.5" 3.0 +/- 0.25" 300 +/- 5psi N/A 1.5 gal.
FRONT 12589751 9.5 +/- 0.125" 7.0 +/- 0.75" 0.5 +/- 0.125" 1050 +/- 5 psi N/A 1.9 gal.
R40
REAR 12599152 4.75 +/- 0.125" 3.25 +/- 0.5" 1.40 +/- 0.125" 495 +/- 5 psi N/A 0.85 gal.
FRONT 12570881 12.0 +/- 0.25" 9.0 +/- 0.5" 2.0 +/- 0.25" 1100 +/- 5 psi N/A 3.0 gal.
R50
REAR 12570880 6.0 +/- 0.25" 4.5 +/- 0.5" 3.0 +/- 0.25" 375 +/- 5 psi N/A 1.5 gal.
FRONT 12584321 11.8 +/- 0.25" 7.93 +/- 0.75" 2.0 +/- 0.125" 1010 +/- 5 psi N/A 3.0 gal.
R60
REAR 12599152 4.75 +/- 0.125" 3.56 +/- 0.5" 2.25 +/- 0.25" 690 +/- 5 psi N/A 1.5 gal.
FRONT 12584321 11.8 +/- 0.25" 7.93 +/- 0.75" 2.0 +/- 0.125" 1010 +/- 5 psi N/A 3.0 gal.
R65
REAR 12599152 4.75 +/- 0.25" 3.56 +/- 0.5" 2.25 +/- 0.25" 690 +/- 5 psi N/A 1.5 gal.
FRONT 12631826 16.0 +/- 0.25" 10.25 +/- 1.5" 2.0 +/- 0.25" 775 +/- 5 psi N/A 4.0 gal.
R85B Old front 12575272 15.25 +/- 0.25" 11.25 +/- 0.5" 2.25 +/- 0.25" 475 +/- 5 psi N/A 5.5 gal.
REAR 12631823 6.5 +/- 0.25" 5.0 +/- 0.5" 3.0 +/- 0.25" 425 +/- 5 psi N/A 3.5 gal.
FRONT 12631826 16.0 +/- 0.25" 10.25 +/- 1.5" 3.5 +/- 0.25" 720 +/- 5 psi N/A 4.0 gal.
R90
REAR 12631823 6.5 +/- 0.25" 5.0 +/- 0.5" 3.0 +/- 0.25" 425 +/- 5 psi N/A 3.5 gal.
FRONT 12568157 16.0 +/- 0.25" 13.00 +/- 1.0" 2.0 +/- 0.25" 1150 +/- 5 psi 1050 +/- 5 psi 7.5 gal.
R120M
REAR 12570013 6.5 +/- 0.25" 5.0 +/- 0.5" 3.0 +/- 0.25" 325 +/- 5 psi 250 +/- 5 psi 4.5 gal.
FRONT 12568157 16.0 +/- 0.25" 12.0 +/- 1.0" 2.0 +/- 0.25" 1150 +/- 5 psi N/A 7.5 gal.
R130
REAR 4087806 7.0 +/- 0.25" 5.0 +/- 0.5" 4.0 +/- 0.25" 300 +/- 5 psi N/A 9.5 gal.
FRONT 12589751 9.53 +/- 0.125" 7.0 +/- 0.75" 0.53 +/- 0.125" 1050 +/- 5 psi 930 +/- 5 psi 1.1 gal.
EH700
REAR 12599152 4.75 +/- 0.125" 3.75 +/- 0.5" 1.4 +/- 0.125" 790 +/- 5 psi 690 +/- 5 psi 0.71 gal.
FRONT 12589751 9.53 +/- 0.125" 7.0 +/- 0.75" 0.53 +/- 0.125" 1050 +/- 5 psi 930 +/- 5 psi 1.1 gal.
EH700-2
REAR 12599152 4.75 +/- 0.125" 3.75 +/- 0.5" 1.4 +/- 0.125" 790 +/- 5 psi 690 +/- 5 psi 0.71 gal.
FRONT 12589751 9.53 +/- 0.125" 7.0 +/- 0.75" 0.53 +/- 0.125" 1050 +/- 5 psi 930 +/- 5 psi 1.1 gal.
EH700-3
REAR 12599152 4.75 +/- 0.125" 3.24 +/- 0.5" 1.4 +/- 0.125" 495 +/- 5 psi 375 +/- 5 psi 0.68 gal.
FRONT 12589751 9.53 +/- 0.125" 7.0 +/- 0.75" 0.53 +/- 0.125" 1050 +/- 5 psi 930 +/- 5 psi 1.1 gal.
EH750
REAR 12599152 4.75 +/- 0.125" 3.75 +/- 0.5" 1.4 +/- 0.125" 790 +/- 5 psi 690 +/- 5 psi 0.71 gal.
FRONT 12589751 9.53 +/- 0.125" 7.0 +/- 0.75" 0.53 +/- 0.125" 1050 +/- 5 psi 930 +/- 5 psi 1.1 gal.
EH750-2
REAR 12599152 4.75 +/- 0.125" 3.75 +/- 0.5" 1.4 +/- 0.125" 790 +/- 5 psi 690 +/- 5 psi 0.71 gal.
FRONT 12589751 9.53 +/- 0.125" 7.0 +/- 0.75" 0.53 +/- 0.125" 1120 +/- 5 psi 1000 +/- 5 psi 1.1 gal.
EH750-3
REAR 12599152 4.75 +/- 0.125" 3.25 +/- 0.5" 1.4 +/- 0.125" 540 +/- 5 psi 420 +/- 5 psi 0.68 gal.
FRONT 12584321 11.8 +/- 0.25" 7.93 +/- 0.75" 2.0 +/- 0.125" 1010 +/- 5 psi 900 +/- 5 psi 1.33 gal.
EH1000
REAR 12599152 4.75 +/- 0.125" 3.75 +/- 0.5" 1.4 +/- 0.125" 790 +/- 5 psi 690 +/- 5 psi 0.71 gal.
FRONT 12584321 11.8 +/- 0.25" 7.93 +/- 0.75" 2.0 +/- 0.125" 1010 +/- 5 psi 900 +/- 5 psi 1.33 gal.
EH1100
REAR 12599152 4.75 +/- 0.125" 3.75 +/- 0.5" 1.4 +/- 0.125" 790 +/- 5 psi 690 +/- 5 psi 0.71 gal.
FRONT 12584321 11.8 +/- 0.25" 7.93 +/- 0.75" 2.0 +/- 0.125" 1010 +/- 5 psi 900 +/- 5 psi 1.33 gal.
EH1100-3
REAR 12599152 4.75 +/- .125" 3.75 +/- 0.5" 1.4 +/- 0.125" 790 +/- 5 psi 690 +/- 5 psi 0.71 gal.
FRONT 12631825 16.0 +/- 0.25" 10.25 +/- 1.5" 3.5 +/- 0.25" 835 +/- 5 psi 760 +/- 5 psi 4.13 gal.
EH1600
REAR 12631823 6.5 +/- 0.25" 5.0 +/- 0.25" 3.25 +/- 0.25" 510 +/- 5 psi 435 +/- 5 psi 3.33 gal.
FRONT 12631825 16.0 +/- 0.25" 10.25 +/- 1.5" 3.5 +/- 0.25" 835 +/- 5 psi 760 +/- 5 psi 4.13 gal.
EH1700
REAR 12631823 6.5 +/- 0.25" 5.0 +/- 0.25" 3.25 +/- 0.25" 510 +/- 5 psi 435 +/- 5 psi 3.33 gal.
* NEOCON VOLUME is given for general information only, in order to ensure proper NEOCON fluid level, the X-4 dimension
must be referenced.

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120 Ton +

NEOCON SUSPENSION SPECIFICATIONS

PART X-2 X-4 NEOCON
MODEL AXLE X-1 P1 P1-A
NUMBER (Truck Empty) (Truck Empty) VOLUME*
FRONT 12631822 16.0 +/- 0.25" 12.0 +/- 1.0" 2.0 +/- 0.25" 1200 +/- 5 psi N/A 9.5 gal.
R150
REAR 4087806 7.0 +/- 0.25" 5.0 +/- 0.5" 4.0 +/- 0.25" 325 +/- 5 psi N/A 9.5 gal.
FRONT 12631822 16.0 +/- 0.25" 12.0 +/- 1.0" 2.0 +/- 0.25" 1200 +/- 5 psi N/A 9.5 gal.
R170ED Optional Front 12579743 16.0 +/- 0.25" 9.0 +/- 1.0" 2.0 +/- 0.25" 900 +/- 5 psi N/A 9.5 gal.
REAR 4087806 7.0 +/- 0.25" 5.0 +/- 0.5" 4.0 +/- 0.25" 325 +/- 5 psi N/A 9.5 gal.
FRONT 12631822 16.0 +/- 0.25" 12.0 +/- 1.0" 2.0 +/- 0.25" 1300 +/- 5 psi N/A 9.5 gal.
R190SD REAR 4087806 7.0 +/- 0.25" 5.0 +/- 0.5" 4.0 +/- 0.25" 450 +/- 5 psi N/A 9.5 gal.
REAR (Opt. HD) 12645280 7.00 +/- 0.125" 5.5 +/- 0.5" 2.875 +/- 0.125" 290 +/- 5 psi 190 +/- 5 psi 9.5 gal.
FRONT 12644742 16.0 +/- 0.125" 12.25 +/- 0.5" 2.0 +/- 0.125" 850 +/- 5 psi 750 +/- 5 psi 8.5 gal.
R260 REAR (Std. Body) 12644696 7.0 +/- 0.125" 5.25 +/- 0.5" 4.5 +/- 0.125" 190 +/- 5 psi 90 +/- 5 psi 12.28 gal.
REAR (Hvy. Body) 12644696 7.0 +/- 0.125" 5.25 +/- 0.5" 4.5 +/- 0.125" 250 +/- 5 psi 150 +/- 5 psi 12.28 gal.
FRONT 12644742 16.0 +/- 0.125" 12.25 +/- 0.5" 2.0 +/- 0.125" 850 +/- 5 psi 750 +/- 5 psi 8.5 gal.
R280 REAR (Std. Body) 12644696 7.0 +/- 0.125" 5.25 +/- 0.5" 4.5 +/- 0.125" 190 +/- 5 psi 90 +/- 5 psi 12.28 gal.
REAR (Hvy. Body) 12644696 7.0 +/- 0.125" 5.25 +/- 0.5" 4.5 +/- 0.125" 250 +/- 5 psi 150 +/- 5 psi 12.28 gal.
FRONT 12631822 16.0 +/- 0.25" 13.0 + 0.0 / - 2.0" 2.0 +/- 0.25" 1200 +/- 5 psi 1100 +/- 5 psi 9.5 gal.
EH3000
REAR 4087806 7.0 +/- 0.25" 5.0 +/- 0.5" 4.0 +/- 0.25" 325 +/- 5 psi 250 +/- 5 psi 9.5 gal.
FRONT 12631822 16.0 +/- 0.25" 13.0 + 0.0 / - 2.0" 2.0 +/- 0.25" 1300 +/- 5 psi 1200 +/- 5 psi 9.5 gal.
EH3500
REAR 12645280 7.00 +/- 0.125" 5.5 +/- 0.5" 2.875 +/- 0.125" 290 +/- 5 psi 190 +/- 5 psi 9.5 gal.
FRONT 12644742 16.0 +/- 0.125" 12.25 +/- 0.5" 2.0 +/- 0.125" 850 +/- 5 psi 750 +/- 5 psi 8.5 gal.
EH4000 REAR (Std. Body) 12618728 7.0 +/- 0.125" 5.25 +/- 0.5" 4.5 +/- 0.125" 190 +/- 5 psi 90 +/- 5 psi 12.28 gal.
REAR (Hvy. Body) 12618728 7.0 +/- 0.125" 5.25 +/- 0.5" 4.5 +/- 0.125" 250 +/- 5 psi 150 +/- 5 psi 12.28 gal.
FRONT 12644742 16.0 +/- 0.125" 12.25 +/- 0.5" 2.0 +/- 0.125" 850 +/- 5 psi 750 +/- 5 psi 8.5 gal.
EH4500 REAR (Std. Body) 12644696 7.0 +/- 0.125" 5.25 +/- 0.5" 4.5 +/- 0.125" 190 +/- 5 psi 90 +/- 5 psi 12.28 gal.
REAR (Hvy. Body) 12644696 7.0 +/- 0.125" 5.25 +/- 0.5" 4.5 +/- 0.125" 250 +/- 5 psi 150 +/- 5 psi 12.28 gal.
FRONT 12644742 16.0 +/- 0.125" 12.25 +/- 0.5" 2.0 +/- 0.125" 850 +/- 5 psi 750 +/- 5 psi 12.0 gal.
EH4500-2 REAR (Std. Body) 12644696 7.0 +/- 0.125" 5.25 +/- 0.5" 4.5 +/- 0.125" 190 +/- 5 psi 90 +/- 5 psi 12.28 gal.
REAR (Hvy. Body) 12644696 7.0 +/- 0.125" 5.25 +/- 0.5" 4.5 +/- 0.125" 250 +/- 5 psi 150 +/- 5 psi 12.28 gal.
FRONT 12644742 16.0 +/- 0.125" 12.25 +/- 0.5" 2.0 +/- 0.125" 850 +/- 5 psi 750 +/- 5 psi 12.0 gal.
EH5000 REAR (Std. Body) 12644696 7.0 +/- 0.125" 5.25 +/- 0.5" 4.5 +/- 0.125" 190 +/- 5 psi 90 +/- 5 psi 12.28 gal.
REAR (Hvy. Body) 12644696 7.0 +/- 0.125" 5.25 +/- 0.5" 4.5 +/- 0.125" 250 +/- 5 psi 150 +/- 5 psi 12.28 gal.
* NEOCON VOLUME is given for general information only, in order to ensure proper NEOCON fluid level, the X-4 dimension
must be referenced.

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 NEOCON STRUT CHARGING MANUAL (HTTHTM-07-1206)

12/21/2006

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