CHAPTER

Suspension
18 Systems

Learning Objectives
After reading this chapter, you should be able to:
n Describe the fundamentals of off-road suspension systems.
n Identify the components that make up off-road suspension systems.
n Describe the principles of operation for off-road suspension systems.
n Outline the maintenance and repair procedures associated with off-road suspension systems.
n Identify the basic troubleshooting procedures for off-road suspension systems.

Key Terms
cross tube load cushion solid rubber suspension
cylinder pressure nitrogen-charged accumulators spring packs
drive bushing oil/pneumatic cylinder suspension cylinder
equalizing beam suspension oscillating hitch torque rods
jounce rebound U-bolt
leaf-spring system saddle assembly unsprung weight

INTRODUCTION well as absorbing shock loads and providing a com-

fortable ride for the operator. A suspension system that
The main job of an off-road suspension system performs well when both loaded and unloaded gener-
(see Figure 18-1) is to support the total weight of the ally has to compromise some performance at both ends
equipment. If no suspension system were used, the of the spectrum. A well-designed suspension system
shock loads encountered during operation would will perform well with or without a load.
be transmitted directly to the equipment’s frame. Off-road suspension systems come in many de-
These jolts would soon cause metal fatigue, resulting in signs. Some are as simple as those found on many
cracks in the frame structure. Equally important is the types of slow-moving LHDs (load haul and dump
comfort of the operator, who in many cases must re- equipment), which consist of drive axles that are
main at the controls for hours on end. Modern sus- mounted directly to the frame with only the tires
pension systems play a major role in providing stability to absorb ground impact. Conventional leaf-spring
to the equipment during operation on rough terrain, as systems are still quite common on many haulage truck

493

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494 Chapter 18

Scraper When working on suspension systems that use gas/

Hitch gooseneck suspension cylinders, ensure that the nitrogen in the
castings cylinders has been discharged before checking the oil
Nitrogen
level. Never remove any plugs or valves from a sus-
accumulators
pension cylinder if the rod is not fully retracted. Do not
work under a suspended load without ensuring it is
properly blocked. When a jack or hoist is to be used,
ensure that it has the rated capacity to lift the load.
When working around heavy equipment, always wear
the required personal protective equipment based on
job conditions.

CAUTION The equipment that you work on

© Cengage Learning 2014

Leveling Orifice will often require you to climb up to a location
valve
where the work will actually be performed.
Oil from tractor Always use the three-point contact rule when
hydraulic system mounting or dismounting the equipment: Main-
tain contact with two hands and one foot, or two
Figure 18-1 Caterpillar cushion hitch suspension feet and one hand. Never attempt to mount or
system used on a 637E scraper.
dismount moving equipment. Do not carry tools
with you when mounting or dismounting the
equipment. Use a hand line or other safe means
applications in pits and quarries. Complex systems
to pull the tools and components up to where
may incorporate nitrogen-filled shocks that are moni-
you are working.
tored and regulated by the operator, or an onboard
ECM (Electronic Control Module) that monitors and
controls the operation of the suspension system. Use only approved lifting devices when hoisting
Terminology associated with heavy-duty suspen- components, and follow the correct procedure.
sion system design and performance uses terms such Figure 18-2 shows what happens to the load capacity
as, sprung and unsprung weight, jounce, rebound, and of a chain or sling when it is used at different angles.
oscillation. Unsprung weight is the total weight of the n Figure 18-2A shows the load rating capacity of
axle plus all the components that are mounted to it, the chain in a vertical position. Load capacity is
including the brake hardware and suspension compo- 100% of its workload rating.
nents. Sprung weight is defined as the load that the n Figure 18-2B shows the load rating capacity of
suspension must support during normal operation. The the chain at a 60-degree angle from vertical.
term jounce is used to identify a spring when it is in its Load capacity is reduced to 86% of its workload
most compressed state. Some manufacturers refer to rating.
the rubber blocks used to prevent axle-to-frame con- n Figure 18-2C shows the load rating capacity of
tact as ‘‘jounce blocks.’’ The term rebound describes the chain at a 45-degree angle from vertical. Load
what happens to the potential energy that is stored in a capacity is reduced to 70% of its workload rating.
compressed spring; it kicks back. On many types of n Figure 18-2D shows the load rating capacity of
equipment, jounce and rebound are controlled with the chain at a 30-degree angle from vertical. Load
dampening devices such as shock absorbers and capacity is reduced to 50% of its workload rating.
springs.
Suspension work on off-road equipment often in- Exercise caution when working with hydraulic sus-
volves the use of heavy lifting devices because the pension systems under high pressure. A technician is
suspension system components are usually heavy. often required to locate hydraulic leaks on these sys-
When working with suspension cylinders, be mindful tems. When checking for hydraulic leaks, never run your
that they may be under pressure and can move sud- hands over the lines and components. High-pressure,
denly without warning. Never place yourself in a po- pin-hole leaks can penetrate the skin leading to serious
sition that could cause you to become pinned between injury. If oil penetrates the skin, immediate medical
a tire and the frame by the sudden movement of a attention is mandatory. In addition, remember that
suspension component. oil operating temperatures on hydraulic suspension

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Suspension Systems 495

2D

30°
2C

2B
45°

© Cengage Learning 2014

2A

Reprinted Courtesy of Caterpillar Inc.

60°

90°

Figure 18-2 Lifting devices used at different angles

will affect the load lifting capabilities. Refer to load
lifting charts to determine the correct slings and
angles.
Figure 18-3 How the suspension cylinder is incorpo-
rated into the front suspension in a typical haulage
systems can exceed 2128F (1008C) which can cause truck.
severe burns.
Appropriate protective equipment must be used
when handling hot oil or components. Hydraulic tanks Oil/Pneumatic Suspension Systems
are often pressurized to prevent dirt contamination and Equipment that is used for haulage operation in pits
require special procedures to check the oil level safely. and quarries often uses independent oil/pneumatic
On equipment that uses high-pressure nitrogen in the suspension systems. These systems on newer haulage
suspension systems, spraying a soap and water solution trucks are complex and require a good understanding
is the only safe way to locate a leak. Compressed ni- of both hydraulics and electrical/electronics funda-
trogen has the potential to cause serious injuries. mentals to service them. This family of large trucks
use a suspension cylinder at each front wheel end
(instead of a conventional kingpin) as part of the
FUNDAMENTALS
steering linkage. The oil/pneumatic cylinders also act
Suspension systems on off-road equipment are as shock absorbers. The front suspension cylinder
designed to absorb road and load impacts by at- barrels are attached to the frame of the equipment at
tempting to isolate them from the frame. Off-road the top and connect to the steering knuckle at the
haulage trucks often use independent suspension bottom, as shown in Figure 18-4. When the equipment
cylinders that are capable of independent rebound is in motion, the front wheels are permitted to move up
rates, as shown in Figure 18-3. This allows the load and down as the terrain changes.
stresses to be absorbed by the suspension instead of The front suspension cylinders contain nitrogen gas
the frame. Off-road equipment operating on rough in chamber 2 (see Figure 18-5), which reacts to wheel
terrain benefits from independent suspension systems movement during operation. As the wheel moves up,
that permit axles to absorb lateral, torsional, and the gas charge in chamber 2 is compressed, forcing
bending forces. oil to flow to chamber 6 through orifice 4 and ball
Suspension systems in off-road equipment have check 5. When the front suspension cylinder moves
distinct categories: Independent oil/pneumatic sus- down during operation (see Figure 18-6), the com-
pension systems are used on haulage equipment, and pressed nitrogen gas forces the rod to move down. The
solid axle suspension systems are used on LHD oil flows from cavity 6 through orifice 4 to chamber 2.
equipment. These systems will be discussed in depth in At the same time, the increase in pressure forces check
this chapter. Designs differ from manufacturer to ball 5 to close off the port, forcing all the oil to flow
manufacturer, but share basic operating principles. through orifice 4 on its way to chamber 2. Orifice 4 is

Copyright 2013 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part.
496 Chapter 18

1 2
Nitrogen

3
Rebound 4
chamber
5

Reprinted Courtesy of Caterpillar Inc.

Cylinder
housing

Nitrogen
Oil
© Cengage Learning 2014

Figure 18-6 Cutaway of a front suspension cylinder

Piston
with the rod moving down: 1. Cylinder, 2. Nitrogen
chamber, 3. Cylinder rod, 4. Orifices (2), 5. Ball check,
6. Cylinder.

Figure 18-4 Cutaway of a suspension cylinder in a

typical haulage truck. at the top with the stem end of the cylinder mounted to
a ball joint at the front of the rear axle housing. This
allows the suspension cylinder to pivot on the differ-
1 ential housing during operation. In other words, the
set-up is opposite from the arrangement used on the
2
front suspension. The rear suspension cylinders sup-
3 port the entire weight of the rear of the haulage truck,
4 including the load.
5 During operation, the rod is able to react to terrain
changes and move up and down in the housing. The
6 compressed nitrogen in cavity 2 provides a cushion
during operation, while the ability to absorb shock
loads is controlled by orifice 5. Check ball 6 controls
the flow rate of the oil between chambers 2 and 4.
Reprinted Courtesy of Caterpillar Inc.

When one of the wheel ends of the rear axle moves up

during operation, the cylinder housing is forced to
move up on the rod (see Figure 18-7). As a result of
Nitrogen
this motion, the nitrogen pressure in cavity 2 in-
Oil creases rapidly to provide a cushioning action. This
increase in nitrogen pressure also forces the oil in
Figure 18-5 Illustration shows a cutaway of a front
cavity 2 to flow to cavity 4 by way of orifice 6 and
suspension cylinder with the rod moving up. ball check 5.
1. Cylinder, 2. Nitrogen chamber, 3. Cylinder rod, When the rear suspension cylinder housing changes
4. Orifices (2), 5. Ball check, 6. Cylinder. direction and moves down, as shown in Figure 18-8,
the combined weight of the vehicle and load along
gradually closed off as the rod extends downward to with the nitrogen in cavity 2 forces the rod to move
prevent the rod from bottoming out in the cylinder. out. The oil in cavity 4 is forced to flow to chamber 2
The rear suspension is similar to the front in that it through orifice 6 as check valve 5 closes due to reverse
also uses oil/pneumatic suspension cylinders. The oil flow. Because of the restrictive flow of oil from
cylinder barrels are connected to the equipment frame cavity 4 to cavity 2, a shock absorber action is

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Suspension Systems 497

1 ARTICULATING TRUCK
2 SUSPENSION SYSTEM
Large articulating haulage trucks, as shown in
3 Figure 18-9, often integrate the suspension system
4 circuit into the vehicle’s hydraulic system which, in
our example, provides oil to the hoist, steering, brake,
and fan drive circuits. A common hydraulic tank
provides oil for all hydraulic circuits on the equip-
ment. On older models, accumulators were used to
6 5 supply stored hydraulic pressure for suspension pres-

Reprinted Courtesy of Caterpillar Inc.

sure. The system was a closed circuit and isolated
from the main hydraulic system by means of control
valves. Newer equipment often uses a similar circuit,
Nitrogen
shown in Figure 18-10, that is able to utilize excess
Oil oil from a brake or hydraulic circuit to control ride
height with the use of directional control valves.
Refer to Figure 18-11 for the following suspension
Figure 18-7 Cutaway of a rear suspension cylinder
circuit identifiers. The suspension frame is connected
with the cylinder moving up: 1. Rod, 2. Nitrogen
chamber, 3. Cylinder, 4. Cavity (2), 5. Ball check, to the front axle on both sides by mounting bolts. The
6. Orifices (2). suspension frame is mounted to each side of the
oscillating hitch by a pin on the upper side at both
ends of the front axle. At the bottom it is attached to
1
the front frame by the lower suspension cylinders’
mounting points along with the rod. Pins, located at the
2 lower end of the suspension cylinders, connect the
cylinders to the suspension frame. Through the use of
suspension frame pivots connected to the oscillating
hitch, independent vertical motion can be achieved.
3 The dampening action of the suspension cylinders is
achieved using nitrogen-charged accumulators.
4
Suspension System Hydraulic
Circuit Operation
5
Reprinted Courtesy of Caterpillar Inc.

In order to raise the suspension system to the de-

6 sired operational height, two control valves must be
activated, as shown in Figure 18-12, with the engine
Nitrogen running so that oil from the main hydraulic circuit can
flow to the suspension cylinders. Once the correct ride
Oil height is reached, the operator closes control valves 9,
which isolates the suspension cylinders so that they
Figure 18-8 Cutaway of a rear suspension cylinder can operate independently. To lower the ride height,
with the cylinder moving down: 1. Rod, 2. Nitrogen the operator opens control valve 10, also shown in
chamber, 3. Cylinder, 4. Cavity (2), 5. Ball check, Figure 18-12, which drain off oil from the suspension
6. Orifices (2). cylinders to lower the ride height. The nitrogen charge
in the accumulators acts like a shock absorber by
cushioning the ride during operation. As the load on
produced in the cylinder. Oil flow from chamber 2 to the suspension cylinders changes with vertical sus-
cavity 4 is much faster during down movement of the pension movement, the pressure in each independent
rod, and slows down considerably in the opposite di- circuit varies up or down, depending on which way the
rection because ball check 5 closes (producing a much suspension cylinder is moving. The gas in the sus-
slower flow rate). pension cylinders increases when compressed during

Copyright 2013 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part.
498 Chapter 18

© Cengage Learning 2014

Figure 18-9 Articulating off-road haulage truck.

Control Upper
valves mounting pin Suspension
Control (16) Front frame cylinder
valves
(15)

From
brake Lower
Accumulators system mounting pin
(14)

© Cengage Learning 2014

Rod

Bolts
Suspension
frame Front axle

Figure 18-11 Typical suspension setup on an articu-

lating haulage truck.
© Cengage Learning 2014

Suspension other three suspension cylinders. Gas-charged sus-

cylinders
pension systems minimize road shock transfer to the
(21)
truck frame. Each wheel is connected to the truck
Figure 18-10 Illustration of a typical suspension frame by a gas/hydraulic suspension cylinder. The
circuit on an articulating truck. suspension cylinders act as kingpins for the steering
system on the front axle. The suspension cylinders
also provide the spring and shock absorber action for
piston-up travel and decreases during piston-down the rear suspension system and dampen suspension
travel. If a leak develops in the nitrogen side of the oscillations.
accumulator, a change in ride height on the side where Key advantages to independent gas/hydraulic
the nitrogen leak has occurred will result. suspension systems are their simplicity of design and
their ability to absorb changing load and road con-
ditions. Gas/hydraulic suspension systems require
Independent Gas-Charged
little maintenance or adjustment when compared to
Suspension Cylinder Maintenance the older conventional leaf-spring systems that they
Many haulage trucks come equipped with inde- are rapidly replacing. Gas/hydraulic suspension sys-
pendent gas suspension systems. Each suspension tems along with operator seat suspensions provide
cylinder works independently so if one cylinder de- operators with a smooth ride and minimal driver
velops a leak, it does not affect the operation of the fatigue.

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Suspension Systems 499

Control may have leaked out of the suspension cylinders,

valves which will affect ride height. Locating external leaks is
Control (10) often difficult and requires the use of a soap and water
valves solution. Check for a loose valve body which can leak.
(9) When checking suspension cylinder operation, look
From for excessive cylinder stem travel. If the chromed area of
braking the stem is clean, this may indicate excessive travel.
Accumulators system Discuss the ride quality with the operator to determine if
(11) there has been any noticeable change. With the equip-
ment unloaded, check the strut height to determine
whether the struts are fully extended; this usually in-
dicates a suspension problem. To correctly diagnose a
suspension system problem, the technician must re-
member that suspension cylinders operate independently
of each other. Suspension cylinders should be serviced
and charged in pairs and cannot be serviced individually.
Conditions for servicing suspension cylinders may
vary somewhat from machine to machine, but gener-
© Cengage Learning 2014
ally will follow the following guidelines. Service is
Suspension required when:
cylinders
(12)
n A suspension cylinder shows signs of external
leakage.
Figure 18-12 Typical suspension hydraulic circuit used n The weight of the truck changes substantially
on a CAT 725 articulating truck. (more than 5,000 pounds).
n The struts are fully extended when the truck is
unloaded.
n The operator complains of a rough ride.
CAUTION Although nitrogen is not flam- n Cylinder pressure varies by more than 50 psi
mable, it can cause serious injuries due to the (345 kPa) from cylinder to cylinder.
high pressures that are used so observe manufac- n The ride height varies more than 0.500" (1.27 cm)
turer’s service literature when working on gas from the specified ride height of the equipment.
cylinders. Do not check the oil level in a suspen-
These dimensions are temperature sensitive so the
sion cylinder until all the nitrogen has been bled
air temperature difference between a shop or building
off. Never remove any valves or plugs from the
where the adjustments are performed must be no
suspension cylinder unless the rod is in the fully
greater than 208F. Table 18-1 lists examples of di-
retracted position.
mensions that would typically be used on haulage
trucks. These dimensions are equipment specific;
Before making adjustments to a suspension system, consult the service literature for the particular type of
the technician must consider that the pressures in each equipment that is to be adjusted.
suspension cylinder can be affected by changes in ride In some cases, a manufacturer will recommend that
height due to leaks at opposite ends of the equipment. a gauge block be fabricated to check the measurements
For example, when the left rear suspension cylinder during the height adjustment procedures. An example
ride height is low, it is likely that the right front sus- of a typical drawing showing the fabrication di-
pension cylinder is riding high because of the shift in mensions is shown in Figure 18-13. Measurements
load weight. A close visual inspection of each cylinder depend on the manufacturing brand of the components.
is necessary to determine the source of the problem. Refer to the equipment manufacturer’s service litera-
Look for oil leaks at the connection points on the ture for specific instructions on the tools required to
suspension cylinders, valves, and the system hoses and perform this adjustment procedure.
pipes. If the vehicle is equipped with an oil distribution Table 18-2 is an example of a manufacturer’s list
manifold and corresponding pressure sensors, check of tools required to charge suspension system com-
for leaks around them. Common sources of leaks are ponents on a typical haulage truck, specific to the
the O-rings used on the distribution manifold. Nitrogen example discussed in this chapter.

Copyright 2013 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part.
500 Chapter 18

TABLE 18-1: TYPICAL DIMENSIONS FOR HAULAGE TRUCKS

Gauge Block Dimensions (Front Suspension Cylinders)

FT Gauge Block Tractor or Truck Gauge Block Length A Gauge Block Length B

1680 771C, 775B 8.50 in. (216.0 mm) 6.69 in. (170.0 mm)

Rear Suspension Cylinder Nitrogen Charge Dimensions (Distance Below the Index Line)

Learning 2014
Quarry Truck First Charge Line Second Charge Line

c Cengage
771C 5.0 in. (128 mm) 5.5 in. (140 mm)
775B 4.9 in. (124 mm) 5.4 in. (137 mm)


25 +
_ 1.0 mm TABLE 18-2: EXAMPLE OF TOOLS REQUIRED
8+
_ 1.0 mm + FOR NITROGEN CHARGING EQUIPMENT
40 _ 2.0 mm
Part Consists Item Number
No. of Description Needed

FT1680 Gauge 2
_ 1.0 mm

7S5437 Nitrogen charge 1

group
8+

1S8941 Hose assembly 1

_ 1.0 mm

7S5106 Chuck 1
7S8713 Gauge 1
A
8+

8S4600 Nipple 2
B 8S1506 Coupling assembly 2
1J3914 Hose assembly 1
7S8712 Gauge 2
7S8714 Gauge 1
© Cengage Learning 2014

2D7325 Tee 1
1S8937 Valve 1
2S5244 Nipple 1
50 +
_ 2.0 mm 8S4599 Coupling assembly 1
8S1505 Regulator assembly 1
Figure 18-13 CAT suspension cylinder height adjust- 5P3041 Nipple assembly 1
ment tool dimensions (refer to Table 18-1 for values).
5P8610 Auxiliary fitting
group
1S8941 Hose assembly 1
Adjusting Rear Gas-Charged 7S5106 Chuck 1
Suspension Cylinders 8S7169 Coupling 2
2J9803 Hose assembly 2
Learning 2014

CAUTION When releasing the pressure in 1S8937 Valve 2

the rear suspension cylinders, the ride height will 5P8998 Pipe nipple 2
c Cengage

decrease quickly so ensure that you will not be 2D7325 Tee 1

trapped between the tire, fender, or frame. 3D8884 90 elbow 1


Note: Auxiliary Fitting Group 5P8610 is used with 7S5437 when

Because both rear cylinders will be charged to- charging two cylinders at the same time. The 7S8712 gauge is
gether, remove both charge valve caps. Install a special used to check the cylinder pressure before charging.

Copyright 2013 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part.
Suspension Systems 501

chuck (7S5106, listed in Table 18-2) on each of the

charge valves as shown in Figure 18-14. Release all Magnet
the nitrogen and oil from the suspension cylinder by
turning the check valve clockwise. Once the cylinders
have bottomed out, allow pressure in the suspension
cylinders to equalize by leaving the check valves open 3
for approximately five minutes. Once the pressure has
equalized, close the check valves by turning counter- 5
4
clockwise. Before attaching the oil fill unit to begin the
fill cycle, make sure the oil lines are full of oil by

© Cengage Learning 2014

cycling the oil refill unit with the ends of the lines
submerged in oil. 6
Before the charging procedure can begin, a rule must
be placed on the cylinder, as shown in Figure 18-15, so
that the cylinder extension can be measured accurately.
A suitable magnet, such as a base for a dial indicator, Figure 18-15 CAT rear suspension cylinder showing
the location of the rule and marks.
should be used to hold the rule in place. The rule should
be placed parallel to the centerline of the suspension
cylinder, as shown in Figure 18-15. A mark must be
TABLE 18-3: EXAMPLE OF NITROGEN
placed on the rule (line 3) that corresponds to the top
CHARGE DIMENSIONS
edge of the suspension cylinder head. Another line (5)
must be placed 1 inch below line 3 on the rule. Once Rear Suspension Cylinders
this is done, mark a corresponding line on the cylinder (Distance Below the Index Line)
(line 4) that matches line 5. Using Table 18-3 to cal-

Learning 2014
culate the dimensions, mark two additional lines Quarry First Charge Second Charge
Truck Line Line
(lines 6) below line 5 (Figure 18-15). Remember, if the

c Cengage
temperature difference is greater than 208F, then a 771C 5.02 in. (127.5 mm) 5.52 in. (140.2 mm)
correction must be made. For every 108F, add 0.100" 775B 4.87 in. (123.7 mm) 5.37 in. (136.4 mm)


(2.54 mm) to the dimension from the example shown
in Table 18-3.
To calculate the correct charge dimension when
the total temperature difference is greater than 208F,
divide the distance to be added (in this case 0.100")
by the temperature increment indicated in the text
(108F) and multiply the result by the Total Tem-
Charge perature Difference (as indicated in the following
valve
example).

Charge
valve cap Note: In the first calculation, we will use
Standard values. Estimate temperatures to the
nearest 108F.

Example for 771C Quarry Truck Rear Suspension.

© Cengage Learning 2014

n Shop ambient temperature: 708F

n Outdoor ambient temperature: –408F
Total Temperature difference between 708F and
–408F = 1108F
Applying the formula indicated previously,
Figure 18-14 CAT rear suspension cylinder showing
the location of the charge valve. 110 F  (0.10"/10 F) ¼ 1.10"

Copyright 2013 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part.
502 Chapter 18

Total length on ruler (refer to Table 18-3) for first Rear Suspension Cylinder Nitrogen
nitrogen charge line: Charge Procedure
5.02" þ 1.10" ¼ 6.12"
CAUTION Nitrogen is the only gas that
(This gives the total distance required between should be used to charge suspension cylinders.
line 3 and the first (upper) of the two lines 6 indicated Gases such as oxygen must never be used because
in Figure 18-15.) oxygen in the presence of flammable materials can
Total length on ruler (refer to Table 18-3) for be explosive. Nitrogen and oxygen cylinders can
second nitrogen charge line: look similar so do not get them mixed up. The
5.52" þ 1.10" ¼ 6.62" fitting used to connect the nitrogen bottles to the
suspension cylinders should never be used on other
(This gives the total distance required between
types of compressed gas bottles such as oxygen.
line 3 and the second (lower) of the two lines 6 indi-
cated in Figure 18-15.)
Mark the results from these calculations on the rule The following procedures are intended for expla-
located on the suspension cylinder before beginning nation purposes only. Always refer to the specific
the charging process. service literature for the equipment to be serviced.
Install the quick disconnect couplings used to
Rear Suspension Cylinder Oil charge the suspension cylinders with oil to the nitrogen
Charge Procedure charge lines of the nitrogen charge kit. Recheck the line
4-to-line 5 alignment on each cylinder to make sure it is
Once the calculations have been made and the data still lined up correctly before beginning the nitrogen
transferred to the rule on the suspension cylinders, the charge procedure. For this next step, the rear suspen-
oil refill unit must be connected to the suspension sion cylinders must be charged with nitrogen until line
cylinders as shown in Figure 18-16. Before starting 4 is lined up with line 6 (see Figure 18-17). Before
the charging procedure, make sure the gate valves are connecting the charge lines to the cylinders, make sure
open on the lines, and then slowly open the check that the charge valves are fully closed; this prevents
valves by turning them counterclockwise. Adjust the the possibility of oil from the suspension cylinders, which
air pressure connected to the oil refill unit to 125 psi is under pressure, getting into the nitrogen charge lines.
(860 kPa). Observe the movement of the cylinders; if Once the previous step has been completed, connect
one cylinder begins to travel at a faster rate than the the charge lines to the rear suspension cylinders, as
other, close the gate valve to the faster cylinder so that shown in Figure 18-18. Adjust the nitrogen regulator
it does not extend beyond line 5 on the rule. Continue located on the charge bottle to 350 psi (2400 kPa). Slowly
filling the other cylinder until it reaches line 5 in open the gate valves, and turn the chucks clockwise on
Figure 18-15. When both cylinders (line 5) are even
with the index (line 4) the oil level is correct. Close the
check valves on the cylinders and close the air and gate Magnet
valves before disconnecting the oil lines.

5
Reprinted Courtesy of Caterpillar Inc.

© Cengage Learning 2014

4 6

Figure 18-17 Height dimension measuring procedure

Figure 18-16 CAT oil refill unit connected to the rear used to charge rear suspension cylinders on a CAT
suspension cylinders. quarry truck.

Copyright 2013 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part.
Suspension Systems 503

Charge
valve

Charge
valve cap

© Cengage Learning 2014

Reprinted Courtesy of Caterpillar Inc.
Figure 18-19 Location of the charge ports on the
front suspension cylinders on a CAT quarry truck.

Figure 18-18 CAT nitrogen charge unit connected to pressurized oil and escaping nitrogen gas can pose a
the rear suspension cylinders. safety hazard to anyone who comes in contact with
either one. Give the pressure in the cylinders a chance to
both suspension cylinders to begin the charging process. equalize by allowing the valves to remain open for
Continue to charge the suspension cylinders until line 4 approximately five minutes before closing them. Once
aligns with line 6, as shown in Figure 18-17. this step is complete, place the charge line ends in a
If the cylinders do not reach the correct height at the suitable container and cycle the oil refill pump until the
same time, close the gate valve on the suspension cyl- lines are full of charge oil. Reattach the lines to the
inder that has reached the correct height dimensions first charge valves on the front suspension cylinders.
and allow the other cylinder to charge until the correct The rule and its corresponding height adjustment
height is reached. Once charging dimensions have been lines are not the same for the front suspension cylin-
reached, close both gate valves before closing the check ders and rear suspension cylinders. Figure 18-20
valves at the suspension cylinders. Remove the nitrogen shows the location of the rule with the appropriate
charge hoses from the suspension cylinders and install scribed lines in place. However, the magnet used for
the protective caps. Torque the caps to the recom- the rear suspension cylinder measurements can be
mended specification outlined in the service literature reused for the front cylinders. Mark up line 3 on the
and remove the steel rules and magnets. rule to correspond with the top edge of the suspension
cylinder’s head. Place a second mark (line 4) on the
cylinder head edge. A third line (5) must be placed
Front Suspension Cylinder 1 inch (25.4 mm) in this case below line 3 on the rule.
Charge Procedures
Although the charge procedures are similar on the
front and rear suspension cylinders, there are some dif-
ferences. The location of the charge ports and the mea-
suring techniques used on the front suspension cylinder
are not the same as those used to adjust the height of the 4 3
rear cylinders. To bleed off the oil in the front suspension
cylinders, remove the charge valve caps, as shown in 5
Figure 18-19, and install the chucks from the oil charge
© Cengage Learning 2014

unit to the charge valves of both suspension cylinders.

Install a suitable drain line to each connection so that
the oil is drained into an appropriate container. While
standing in a safe location, slowly open the check
valves on the charge valves by turning in a clockwise
direction, allowing the oil and nitrogen to bleed off until Figure 18-20 Height dimension measuring procedure
the cylinder reaches the bottom of its travel. Note that used to charge the front suspension cylinders.

Copyright 2013 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part.
504 Chapter 18

Once these steps are complete, you are ready to begin 25 +

_ 1.0 mm
the oil charge procedure steps. 8+
_ 1.0 mm
40 +
_ 2.0 mm
Oil Charge Procedure for the Front
Suspension Cylinders
The following procedures are intended to be used

_ 1.0 mm
for demonstration purposes only. Always refer to the
OEM service literature for the equipment that you will

8+
be servicing.

_ 1.0 mm
The procedure is similar to that used to charge the
rear suspension cylinders. The same specialized tools
are required to perform this next step. Attach the check

8+
A
valves and lines from the oil charge unit to the front
suspension cylinder charge valves. Adjust the air B
pressure to 125 psi (860 kPa) and make sure the gate
valves are in the open position.
Open the check valves slowly by turning in a
clockwise direction. Continue injecting oil until line 5

© Cengage Learning 2014

reaches line 4. If one cylinder reaches the line first,
close the gate valve to that cylinder and allow the
remaining cylinder to fill until it reaches the correct
height. Close the gate valves and regulated air pressure
50 +
_2.0 mm
before bleeding the air pressure to zero. If required,
reuse of the quick disconnects is allowed to charge the Figure 18-21 Dimensions to fabricate the gauge used
suspension cylinders with nitrogen if they are not in- to measure the front suspension cylinder height on a
cluded with the nitrogen charge kit. CAT quarry truck.

be adjusted by adding shims of a predetermined thick-

Nitrogen Charge Procedure
ness (in this case, 3.3 mm). Calculate the correct charge
for the Front Suspension Cylinders dimension in the same way as described for rear sus-
The use of gauge blocks to set the correct ride height pensions: when the temperature difference is greater than
on the front suspension cylinders in this example is 78C, divide the distance to be added (in this case 3.3 mm)
shown to clarify the steps required to perform this pro- by the temperature increment indicated in the text (78C)
cedure. Figure 18-21 shows an example of gauge blocks and multiply the result by the Total Temperature Dif-
that are used to set the ride height. This requirement may ference (as indicated in the following example).
vary depending on the manufacturer and model of
equipment. Suspension dimensions will be affected by
temperature differences between the adjustment location Note: When the temperature difference is
and the operating location. For example, if the temper- greater than 78C, the nitrogen charge dimen-
ature difference between the shop where the adjustment sions should be adjusted by a correction
is performed and the outside temperature where the amount by adding additional shims.
equipment is operating is greater than 208F, a different
calculated dimension is required for extra shim thickness
When the difference between the outside ambient
and must be calculated based on the temperature dif-
temperature and temperature in the shop is greater than
ference. An example of this calculation is provided for a
78C, then add 3.3 mm of shim thickness to each gauge
typical haulage truck but the procedures and dimensions
block for every 78C difference in temperature.
for different manufacturer’s equipment or even different
models by the same manufacturer can vary substantially.
Example for 771C Quarry Truck Front Suspension.
Gauge blocks are used when the total difference be-
tween the shop and the outside ambient temperatures is
78C or less. When the total temperature difference is Note: Estimate temperatures to the nearest 78C.
greater than 78C, the nitrogen charge dimensions should

Copyright 2013 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part.
Suspension Systems 505

n Shop ambient temperature: 208C vehicle, raise the truck body, and steer the wheels from
n Outdoor ambient temperature: –408C side to side to facilitate removal.
Total Temperature Difference between –408C and
208C = 608C REUSE OF GAS/HYDRAULIC
Apply the formula indicated previously to deter- SUSPENSION SYSTEM
mine needed shim thickness: COMPONENTS
60 C  (3:3 mm/7 C) ¼ 28 mm The suitability to reuse components in a suspension
Gauge block (refer to Table 18-1) plus shim thickness: system can be determined by following the manu-
facturer’s service literature. Welding and re-machining
170 mm þ 28 mm ¼ 198 mm of the seal lands is often done to the head of the rear
This gives the total distance that should be used for suspension cylinder housing. The rod assemblies are
Gauge Block length B (see Table 18-1) when adjust- often sent out for re-chroming or polishing to restore
ing the front suspension to the correct ride height. the finish. The cylinders themselves can often be
honed out or re-tubed. Follow the guidelines provided
Procedures. The following procedures are intended by the manufacturer to determine the reusability of
to be used for example purposes only. suspension components.
Ensure that the charge valves are fully closed before When determining the reuse of suspension cylin-
connecting the nitrogen charge lines to the suspension ders, take into consideration the overall length of the
cylinders to prevent oil from entering the nitrogen cylinder, the bore dimensions, the bore finish, and the
charge lines. The first step is to adjust the nitrogen internal diameter of the connecting eyes. The cylinder
regulated pressure to 600 psi (4,150 kPa). Next, open the rods must meet specific tolerances as well. The overall
gate valves on the high-pressure lines, allowing the ni- length of the cylinder rod as well as the outside di-
trogen to flow to the charge valves. Slowly open the ameter of the rod must be within specifications. The
charge valve check valves by turning clockwise on both rod eye dimensions must be within specifications;
suspension cylinders to allow nitrogen to enter the cyl- often the eye will have a replaceable bushing.
inders. If one of the cylinders extends faster than the
other and has reached slightly higher than the correct LOAD, HAUL, AND DUMP RIDE
height, close the gate valve to that cylinder and continue CONTROL SUSPENSION SYSTEMS
to allow the other cylinder to reach the same height
before closing the remaining gate valve. In this example, Off-road load, haul, and dump equipment, as
continue to inject nitrogen into the suspension cylinders shown in Figure 18-22, uses only the tires to absorb
until they reach the same height (6.69 in.). road shock. Because of the slow operating speeds of
Close off both gate valves first, and then close the this type of equipment and the specific work that this
charge valves on the suspension cylinders. Remove the equipment performs, conventional suspension systems
lines at the quick disconnects. With the gauge blocks are not necessary. The front axles (bucket end) on this
and shims in place, slowly open the charge valves to type of equipment are bolted solidly to the frame with
release some of the nitrogen until the cylinder comes the only shock absorbing capability coming from the
to rest on the gauge block. At this point, close the tires themselves.
charge valve.
Reconnect the nitrogen charge lines to the sus-
pension cylinders and adjust the regulated nitrogen
pressure to 350 psi (2,400 kPa). Once the previous
steps have been completed, open the gate valves and
charge valves and allow the nitrogen to flow into the
Reprinted Courtesy of Caterpillar Inc.

suspension cylinders for approximately five minutes to

equalize the pressure. After the pressure has been
equalized, close the charge valves and gate valves and
close the nitrogen supply at the tank.
Disconnect the nitrogen charge kit from the sus-
pension cylinders, reinstall the protective valve caps,
and torque to specifications. If the gauge blocks are not
easy to remove, it may be necessary to start the Figure 18-22 Typical load, haul, and dump vehicle.

Copyright 2013 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part.
506 Chapter 18

The rear axles are bolted to an oscillating axle or RIDE CONTROL SUSPENSION
rear axle trunnion bearing support, as shown in SYSTEM TESTING AND
Figure 18-23, which pivots on large bushings running ADJUSTING
lengthwise along the length of the equipment. This
allows the equipment to maintain road contact during The ride control circuit can be serviced by using the
operation on uneven ground. following procedure. Start the equipment and switch on
Some manufacturers offer an option for a load ride the ride control option. With the joystick control lever,
control. This allows the loader bucket to ride on a lower the bucket to the ground and place the lever in the
column of oil in the hoist cylinders that are connected float position. This step relieves the hydraulic pressure
hydraulically to an accumulator through a control in the ride control accumulator. Once this step is com-
valve, allowing road shock to be absorbed by the ac- pleted, the equipment can be shut down and the hy-
cumulator. A control switch located on the dump hoist draulic lines to the accumulator can be safely removed.
control lever is used to activate the ride control circuit. If the accumulator needs to be replaced, open the
Figure 18-24 shows the ride control circuit in the gas discharge valve on the accumulator one turn to
inactive position, solenoid 7, which is a normally release all the compressed nitrogen gas in the accu-
closed valve blocking the flow of oil from the pilot mulator gas chamber.
circuit to the diverter valve 8. When the lift control
valve solenoid is energized, and the lift control valve Charging the Accumulator
is in the hold position, pilot oil flows to the diverter
The following procedures are used for example
valve, forcing the spool inside to shift to the left. With
purposes only. Refer to the specific equipment service
the diverter valve in this position and the control
literature for the actual service procedures. Be sure that
valve in the hold position, the oil from the head end
the charge valve is fully closed before connecting the
and the rod end of the lift cylinder flows through the
nitrogen charge lines to the accumulator to prevent oil
right side of the diverter valve. The oil from the head
from entering the nitrogen charge lines.
end of the lift cylinder flows directly into accumulator 6.
The equipment must be started, warmed up, and
The rod end oil returns to the tank through the diverter
left running to perform this procedure. To charge the
valve.
accumulator with dry nitrogen, perform the following
When the equipment is operated on rough ground
steps in order:
with a full bucket, the combined weight of the bucket
and load act on the oil in the lift cylinder head end, 1. Locate the ride control accumulator and remove
which is open to the accumulator. The nitrogen pre- the guard that protects the gas charge valve and
charged accumulator absorbs the shock loads, acting remove the cap.
like a shock absorber. The rod end receives makeup oil 2. Before you can attach the nitrogen charge
since it is open through the diverter valve into the lift adapter to the valve, the T-handle must be
cylinders. turned all the way out (counterclockwise) be-
fore connecting the chuck to the accumulator.
3. Connect the chuck (5) to the accumulator
charge valve (see Figure 18-25).
4. This step requires the gas in the accumulator to
be discharged to the atmosphere. Connect the
quick disconnects (3) and (13) together and
place the open end of the hose in such a way
that the discharge will not harm anyone.
5. Open the T-handle (4) and valve (1) and raise
the lift arms of the equipment. This forces
the gas in the accumulator to be expelled to the
© Cengage Learning 2014

atmosphere. Be sure that the open end of the

hose is not pointed toward anyone.
6. Place the needle valve (1) in the open position.
Turn the T-handle (4) on the gas chuck (5)
clockwise all the way in.
Figure 18-23 Typical loader with rear oscillating axle 7. Ensure that no one is positioned near the bucket
during operation on uneven ground. end of the equipment and that adequate

Copyright 2013 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part.
Suspension Systems 507

1
4 5 6
To ride
2 3 control
switch
7

Dump Crowd Lower Lift

From steering
neutralizer valve
From steering
control valve
To Hand From hand
metering unit metering unit

10 11

© Cengage Learning 2014

To steering 12
control valve
To transmission
oil reservoir
Torque converter
oil reservoir

Figure 18-24 Ride control circuit used on a load, haul, and dump loader.

headroom is available to raise the bucket to its the joystick in the float position, and move the
maximum height. Lift arms must be raised to ride control switch to the on position.
their maximum height and held for five seconds. 9. Connect the quick disconnect couplings (10) and
This step ensures that all the gas has been (11) and attach the hose to the nitrogen cylinder.
vented from the accumulator and the accumu- 10. Adjust the nitrogen pressure (9) to 300 psi ± 5 psi
lator piston has moved all the way up. (2,070 kPa ± 35 kPa). This pressure is based
8. Close the needle valve (1) after all the gas on an ambient temperature of 708F (218C). To
pressure in the accumulator has been released to compensate for temperature differences, con-
the atmosphere. Place the joystick in the hold sult the service literature for the equipment
position. Lower the bucket to the ground, place being serviced.

Copyright 2013 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part.
508 Chapter 18

T handle (4) register on the gas pressure gauge. If a lower

pressure is observed on the gauge, then the ac-
cumulator has not been properly charged and
Chuck (5) the charge procedure must be redone.
14. If the hydraulic system relief pressure was
Quick Pressure reached, lower the bucket to the ground and
disconnect gauge (2)
Quick coupling place the ride control switch in the on position.
disconnect male (3) 40
30
50
60 70 80
90
100
110
Observe that the nitrogen gas pressure drops
instantly to charge pressure. If the nitrogen gas
20

female (13)
120
10 130
0 140

pressure has not dropped to the charge pressure,

EN
repeat the charge procedure until this occurs.
OP

CL

15. Remove the charge hardware and install the cap

O

SE

Hose Needle and protective cover back onto the accumulator.

assembly (12) valve (1)
Pressure 50
60 70 80
Installing a New Accumulator
90

gauge (6) 40
30
20
100
110
120
40
30
50
60 70 80
90
100
110
10 20

When installing a new accumulator on the ride

120
130
10 130
0 140
0 140

control system, certain steps must be observed so that

all the air is removed from the nitrogen end of the
accumulator. Pour approximately 2 quarts (1.9 litres)
of hydraulic oil into the nitrogen end of the accumu-
Quick Regulator
© Cengage Learning 2014

disconnect Quick assembly (9) lator. The oil ensures that all the air from the nitrogen
male (11) disconnect end of the accumulator is removed and lubricates the
female (10) Pressure upper seal of the accumulator piston.
regulating Nitrogen cylinder
screw (8) valve (7) 1. Connect the nitrogen gas chuck to the accu-
mulator charge valve and connect the male and
Figure 18-25 Hardware required to charge the ride female quick disconnects together (3 and 13), as
control accumulator. shown in Figure 18-25. Place the open end of
the hose in a suitable container to collect the oil.
2. Open the needle valve (1) and screw the T-handle
Note: If the equipment has been in opera- on the gas chuck in a clockwise direction until it
tion, the temperature of the accumulator may is fully open. Make sure that the accumulator is in
be higher than the ambient temperature in the upright position and move the piston to the
which case, use the accumulator temperature. nitrogen end of the accumulator.
3. The air and oil will be vented out of the accu-
mulator as the piston moves up. When the oil
11. Open the needle valve (1) and observe the time
flow stops, close the needle valve completely and
it takes the gauge to reach charge pressure. If
allow any remaining oil to drain from the hose.
the gauge reads the charge pressure instantly,
4. Reconnect the quick disconnect couplings
the gas charge was not properly relieved and all
(10 and 11). Connect the nitrogen charge hard-
of the previous steps must be repeated. If the
ware to the nitrogen bottle and adjust the pres-
gauge takes 10 to 20 seconds to register the
sure to 300 psi (2,070 kPa). Check the ambient
charge pressure, then the gas has been suc-
temperature chart and compensate if required.
cessfully removed from the accumulator.
5. Charge the accumulator by opening the needle
12. Do not remove the line from the accumulator before
valve (1) with 300 psi (2,070 kPa). Close the
turning off the nitrogen gas supply. This ensures
gas chuck (5) and remove the nitrogen charge
that the accumulator piston is bottomed out, and the
hardware from the accumulator. The accumu-
accumulator is completely filled with nitrogen.
lator is now ready to install.
13. Place the ride control switch in the off position,
raise the lift arms, and hold the control lever in
the raise position for about five seconds. This
Checking Charge Pressure
ensures that the pressure reaches and maintains The charge pressure in the ride control accumulator
the system relief valve setting, which should may need to be checked periodically or whenever a

Copyright 2013 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part.
Suspension Systems 509

performance problem is suspected. It is not necessary

to follow all the steps outlined in the charge procedure
just to check the pressure in the system. The following
steps explain how to check the charge pressure
quickly. Start up the equipment and place the ride
control switch on the joystick in the on position. Lower
the bucket to the ground and place the joystick in the
float position. This ensures that all the hydraulic
pressure is relieved in the ride control accumulator.

© Cengage Learning 2014

1. Shut down the equipment and remove the guard
and protective cap from the accumulator.
2. Close the needle valve (1) on the nitrogen
charge hardware and connect the chuck to the
accumulator charge valve. Be sure to turn the Figure 18-27 Articulating haulage truck.
T-handle completely counterclockwise before
connecting the chuck to the accumulator
charge valve. systems have proven to be up to the task of operating
3. Open the T-handle by turning clockwise and read in rough service applications. To maintain good
the gauge (2) to determine whether the accumula- ground contact, the equalizing beams are allowed to
tor pressure is within specifications. If the equip- flex on pivots. This provides a means of balancing the
ment has been in operation, then the temperature loads imposed on the drive axles while still main-
charts, shown in Figure 18-26, must be consulted taining good ground contact.
to determine the correct pressure reading. There are two distinct types of equalizing beam
suspension designs: the leaf-spring equalizing beam, as
shown in Figure 18-28, and the solid rubber equaliz-
EQUALIZING BEAM SUSPENSION ing beam, as shown in Figure 18-29. The latter beam
SYSTEMS is the most common on off-road equipment. This de-
Tandem drive applications that are used on artic- sign is ideally suited to off-road equipment as the
ulating haulage trucks often use equalizing beam layout actually lowers the center of gravity by placing
suspension systems, as shown in Figure 18-27; these the beam below the centerline of the axle. Torque rods
are provided to absorb additional torque generated by
the axle and road shock.
CHARGING PRESSURE AND TEMPERATURE
RELATIONSHIP FOR THE ACCUMULATOR
Temperature °C (°F) Pressure kPa (psi)*
SOLID RUBBER SUSPENSION
–7 (20) 1790 (260) SYSTEMS
–1 (30) 1835 (266)
This design is the most popular type of equalizing
4 (40) 1875 (272) beam suspension on off-road haulage trucks. A solid
10 (50) 1915 (278) rubber suspension incorporates solid rubber load
16 (60) 1955 (284) cushions instead of leaf springs to absorb road shock.
21 (70) 2070 (300) A saddle assembly on each side of the suspension
27 (80) 2110 (306) system holds the rubber load cushions. Figure 18-30
shows a typical rubber cushion equalizer beam sus-
32 (90) 2150 (312)
Reprinted Courtesy of Caterpillar Inc.

pension system. Each of the four rubber blocks is

38 (100) 2200 (318) connected to the axle assembly by drive pins. The
43 (110) 2250 (324) operational loads generated by cornering and braking
49 (120) 2300 (330) are all absorbed by the suspension through these pins.
When the suspension is operating with no load, the
*Nominal allowable pressure tolerance
equals ± 35 kPa (± 5 psi)
outer edges of the spring load cushions are in contact
with the saddle. As the load increases on the vehicle,
Figure 18-26 Temperature compensating chart used the load cushion is compressed, further absorbing the
to charge an accumulator. additional loads. Alignment is maintained by the drive

Copyright 2013 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part.
510 Chapter 18

Torque rod
frame bracket

Rubber bushed Rear

torque rod spring hanger
Front
spring hanger
Additional
spring hanger

Leaf spring

Saddle
assembly Cross
tube

© Cengage Learning 2014

Rubber
center bushing
Equalizer
beam

Figure 18-28 Leaf-spring equalizing suspension system.

Torque rod
frame bracket
Rubber bushed Frame
torque rod hanger

Rubber
load Saddle Load
cushion cushion

Saddle
assembly Cross
© Cengage Learning 2014

tube Full load

No load
Center
bushing Equalizer Load
beam cushion
Figure 18-29 Solid rubber equalizing suspension
system. Saddle
© Cengage Learning 2014

Vertical drive
pins, which are encased in rubber bushings. The ver- bushing
tical drive bushings are used on each drive pin to Vertical
allow vertical movement during loading and unloading drive pin
while still maintaining suspension alignment. This
design works well when loaded, but tends to give a Figure 18-30 Rubber cushion-type equalizing beam
rough ride when operating without a load. suspension system.

Copyright 2013 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part.
Suspension Systems 511

SERVICING SUSPENSION
SYSTEMS
Equalizer
Off-road equipment operates in severe-duty ser- bracket
vice, making regular inspections of the suspension
systems essential. The equipment should be power
washed before regular inspection and servicing. Power
washing the suspension system allows detailed in-
Equalizer
spection of the suspension components, which includes
looking for cracks or physical damage. Rubber bush-
ings should be inspected for deterioration and crack-
ing. If the rubber components show any signs of

© Cengage Learning 2014

deterioration or cracking, they should be replaced as
soon as possible. Suspension system bushings are not
easily removed; specialized tools may be required to
remove them. The use of a torch is not recommended
because the fumes produced by the burning rubber
compounds are toxic. Because a specialized hydraulic Figure 18-31 Misaligned spring rubbing against an
press is often required to remove the bushing and equalizer bracket.
sleeve assemblies, it may be easier to replace the
complete equalizer arm. Press pressures may be as housing, indicating a need for a suspension alignment
high as 50 tons. check.
The load cushions on equalizer beam suspension When a broken or cracked spring is found in a
systems are easily inspected because they are visible. spring pack, most manufacturers recommend that the
Rubber block compounds may be damaged by clean- complete spring pack be replaced. Never apply grease
ing solvents, so be sure to use only manufacturer- or paint to the spring leaves, because this will reduce
approved cleaning products. Visual inspection is all the spring self-dampening ability. The same is true if
that is required to check these components. spring leaves are rusted. Rusted spring packs should be
Check to see if the unsprung height has changed disassembled and cleaned or replaced if cleaning is not
significantly. Operation of equipment with worn-out possible.
load cushions is not recommended because it can Spring and bracket bushings are considered high-
damage the suspension system and frame. maintenance items and should be inspected for cracks
U-bolts that secure the spring packs must be and gouging on a regular basis. If the bushings are
checked for tightness on a regular basis. If the bolts free from damage, their dimension specifications
are corroded, cleaning them and freeing them up be- should be checked. The manufacturer’s recommended
fore checking the torque is required because corrosion dimensions and clearances should be referenced but a
will affect the re-torque values. When new fasteners general rule is a maximum of 0.020" (0.5 mm)
are installed on suspension systems, it is recom- clearance between the bushing and pin. Clearance
mended that the fasteners be re-torqued after a run-in exceeding 0.020" (0.5 mm) usually requires the
period. bushings and pins to be replaced.
If a grease fitting on a spring pin does no take
grease during a scheduled maintenance service, re-
move the weight from the spring and use a hand grease
TROUBLESHOOTING TIPS
gun (capable of generating higher pressures) before The guidelines provided in this chapter are exam-
replacing the fitting. Lubricating the suspension pins is ples and are not intended to be used as a comprehensive
critical to increasing the life span and controlling the troubleshooting guide. Follow the specific trouble-
operating costs of equipment and should always be a shooting procedures that are outlined in the manu-
priority during servicing. facturer’s service literature. Take care when evaluating
Figure 18-31 shows how wear to the equalizer failures; similar but different complaints can often be
bracket can occur when the spring ends shift. Check attributed to the same symptoms. Table 18-4 is a
for loose U-bolts or problems with the U-bolt seating troubleshooting chart that can be used to assess the
when these conditions are encountered. Wear can be most common types of complaints that may develop on
caused by improperly mounted springs on the axle leaf-spring suspension systems.

Copyright 2013 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part.
512 Chapter 18

TABLE 18-4: LEAF-SPRING SUSPENSION SYSTEM TROUBLESHOOTING GUIDE

Symptoms Cause Corrective Action

Equipment leans to Broken spring leaves Replace the spring assembly

one side Spring assembly weak Replace the spring assembly
Bent or twisted from rail Correct the frame rail bend or twist
Spring load capacities are not the Replace the spring assemblies with the
same on both sides of the recommended assemblies
equipment
Equipment wanders Broken spring leaves Replace the spring assembly
Wheels not properly aligned Redo the wheel alignment according
to manufacturer’s recommendations
Incorrect caster settings Adjust caster to manufacturer’s
recommended settings
Steering gear not centered Center the steering
Drive axle alignment not Align the drive axles according to
properly set manufacturer’s recommendations
Equipment suspension Equipment overloaded Follow equipment recommended load
bottoms out during capacity rating
operation Broken spring leaves Spring assembly should be replaced
Weak spring assemblies Spring assembly should be replaced
Spring breakage Equipment overloaded or Equipment load should be reduced
occurs regularly extremely rough service duty to match operating conditions
Insufficient center bolt torque Re-torque center bolt to manufacturer’s
recommended values
Improperly torqued U-bolt nuts Re-torque the U-bolt nuts to
manufacturer’s recommended values
Worn-out or damaged spring pin Replace the spring pins and bushings
bushings allowing spring endplay
Excessive spring noise Improperly torqued spring center Inspect components for damage and
bolt or U-bolts allow excessive replace any damaged parts before
spring movement re-torquing to manufacturer’s
recommended values
Loose, bent, or broken spring Replace the damaged components

Learning 2014
shackle as required and torque the fasteners
to the manufacturer’s recommended
values
c Cengage

Spring pin bushing worn out or Replace the worn or damaged spring
damaged causing excessive spring pins


ASSEMBLY, DISASSEMBLY, AND 2. Use an approved lifting device to raise the

REPLACEMENT PROCEDURES equipment to relieve the weight from the
springs, and place safety stands under the frame.
General Guidelines for Leaf-Spring 3. If shocks are used, disconnect and remove them.
Replacement 4. Remove the U-bolts and retainers along with the
spring bumpers.
The guidelines shown here are for example pur-
5. If the pins are lubricated, remove the grease
poses and should not replace the manufacturer’s
fittings and lubricators.
procedures.
6. Remove the nuts that secure the spring shackle
1. Place the appropriate chocks under the wheels pins.
to prevent the equipment from moving 7. Remove the bracket and shackle pins by sliding
unexpectedly. the spring off the bracket pin.

Copyright 2013 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part.
Suspension Systems 513

8. To install the new spring, fasten the pivot end of

the spring to the frame bracket first.
9. Fasten the shackle or slipper end by aligning it
with the other frame bracket.
10. Install the U-bolts to secure the springs to the
axle, but do final torque until the load is on the
springs.
11. Remove the frame supports to place the springs
under tension, and torque the U-bolts and other
hardware to specification.
12. After replacing spring components, re-check the
torque values after a short break-in period.

CAUTION Caution should be exercised

whenever replacing springs. Leaf-spring packs

Courtesy of Daimler Trucks North America

are under considerable tension and can blow
apart unexpectedly if a center bolt were to break
while being torqued, when the U-bolts are not in
place. When spring pins are removed, ensure that
the equipment is properly mechanically blocked.

Guidelines for Equalizer Figure 18-32 Exploded view of a typical equalizer

Replacement assembly.

Suspension equalizer replacement requires that the

front wheels of the equipment be properly chocked to
damage or the dimensions are excessive, they
prevent unexpected movement during the replacement
should be replaced. Refer to the service lit-
procedure. Use an appropriate floor jack to raise the
erature for the equipment for the correct
rear of the equipment so that the axles can be sup-
specifications.
ported on safety stands in such a way that the weight is
5. Before re-installing the bushing, lubricate its
removed from the leaf springs. Once the equipment is
inside bore with chassis grease and then install
properly blocked, remove the wheels from the axles
the equalizer into the equalizer bracket.
and store in a safe location.
6. Before installing the equalizer cap and tube
1. If the equipment being worked on has a tandem assembly, apply grease to the appropriate area
axle, the cotter pin from the outboard end of and insert the cap and tube assembly into the
each spring retainer should be removed. Now, equalizer through the bracket. Force the equal-
the retainer pins can be removed. izer cap and tube assembly partway into the
2. Loosen and remove the nut from the equalizer equalizer and install the inboard wear washers
cap and tube assembly. Remove the inboard between the inboard equalizer bushing and the
bearing washer, bolt, and outboard bearing bracket. Complete the installation by pushing
washer as shown in Figure 18-32. the cap and tube assembly the rest of the way
3. Place an appropriate bar between the tube as- into the equalizer bracket.
sembly and equalizer cap and pinch the equal- 7. Install the equalizer outer bearing washer on to
izer cap to remove the weight of the equalizer. the equalizer cap and tube assembly bolt before
Position a short piece of pipe through the in- installing it into the cap and tube assembly.
board equalizer cap and tube assembly bolt 8. Install the inboard bearing washer, locknut, and
hole. Gently tap the cap and tube assembly out tube assembly bolt, and torque the nut to
of the equalizer. specification.
4. At this point, the equalizer bushings should be 9. Reinstall the wheels and raise the equipment to
cleaned so that they can be inspected for dam- remove the safety stands from under the frame
age and wear. If the bushings show evidence of and axles. Lower the equipment to the floor.

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514 Chapter 18

10. Before the equipment can be returned to ser- their location. It is good practice to reinstall parts in
vice, the rear axle alignment must be checked the same location from which they were removed.
and adjusted, following manufacturer’s recom- Next, remove the four saddle caps that are used to
mended procedures. lock the center bushing of the equalizer beams to the
saddle assemblies (see Figure 18-33). The torque
rods must be disconnected from the axle housing by
Equalizer Beam Bushing Service
loosening the lock nuts and driving the shaft from the
When any type of replacement work on suspension bushing and axle housing brackets. A suitable hoist is
systems is considered, the area must be thoroughly required to lift the truck frame so that there is suffi-
power washed and cleaned so that the components can cient clearance for the lower part of the saddle to clear
be inspected for physical damage and fatigue cracks. If the top of the axle housing. Ensure that the axles re-
the rubber bushings show any signs of cracking or main properly blocked so that they do not pivot on the
deterioration, they should be replaced. In most cases, wheels. Use safety stands or approved blocking to
specialized service tools are required to replace the support the equipment frame.
equalizer beam bushings. If however, the specialized
tools are not readily available, then a portable hy-
draulic press and the appropriate steel piping can be
used to replace the equalizer beam bushings.
The load cushions or jounce blocks should be in-
spected for signs of distortion or damage. These blocks
act as shock load insulators and are important to the
operation of the suspension system. When cleaning this
area, do not expose the load cushions to cleaning
chemicals because they can be easily damaged by these
products. When visually inspecting the load cushions,
check that the blocks are still bonded to the metal insert
and are not about to separate. If the unloaded height of
the load cushion is less than 1 4 inch (6 mm) below that
/

of a new one, it must be replaced.

Reconditioning Equalizing Beam

Suspension Systems
Clean the equipment before visually inspecting it. It
may be important to ensure that the replacement parts
are available to avoid unnecessary down-time. Before
beginning major suspension repair work, the technician
should read over the procedure in the service literature
and make a note of any special tools required.
Equalizer beams are manufactured from different
materials, some of which are damaged when manu-
facturer service procedures are not adhered to. Care
Courtesy of International Truck and Engine Corporation

should be taken to avoid damaging aluminum and cast

steel equalizer beams. Nodular iron equalizer beams
should be installed in so that the markings indicating
‘‘up’’ (or and arrow) face in the correct direction.
Reinforced gate pads are built into each end and the
middle section of the beams.
After inspection and the parts required to complete
the repairs are in place, the repair can begin. Locate
the equipment on a level, clean, and hard surface.
Place wheel chocks on both axles of the equipment. Figure 18-33 Exploded view of an equalizing beam
Remove the driveshafts from the rear axles and mark suspension assembly.

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Suspension Systems 515

Leaf-Spring Equalizer Beam locknut on the spring pin draw key, as shown
Disassembly in Figure 18-33.
8. Caution must be exercised in this step. The
Although there are several design variations of threads on the draw key can be easily damaged.
equalizer beam mounting configurations, only one of Back off the nut just enough to protect the draw
the three most common types, the bolt-type beam end key threads before tapping the nut with a soft-
mounting, will be used as an example. This mounting blow hammer to loosen the draw key.
is shown in Figure 18-34. This section explains the 9. After the draw key has been removed, drive
procedure used to disassemble the leaf-spring equal- the spring pin out of the spring bracket and
izer beam suspension. lower the spring assembly from the frame us-
1. Disconnect the equalizer beam from the axle ing the jack.
housing before removing the equalizer beam
end bolt. Leaf-Spring Equalizer Beam
2. Drive the bushing adapters and sleeve out of the Assembly
bushing and axle housing brackets using a chisel.
The notches in the adapters will help locate and 1. Position the spring in the spring saddle in such a
keep the chisel in place during this operation. To way that the bolt head of the spring center bolt
wedge out the adapter, drive the chisel into one is located in the hole in the saddle.
side first and then into the other. 2. Place the spring top pad over the cup on the
3. Remove the first adapter and proceed to re- main spring leaf, and install the bolts and nuts
move the opposite adapter with a hammer and that secure the saddle to the top pad. Seat the
drift. nuts on the bolts, but do not torque them yet.
4. Now, the equalizer beams can usually be sepa- 3. To align the spring in the saddle, tighten the
rated from the cross tube. The cross tube pivots spring aligning set screws to the recommended
on the inner sleeve of the center bushing and torque; then tighten the aligning screw locknuts
slides back and forth approximately 3 inches. in place before torquing the saddle to top pad
This results in the cross tube having a polished bolt nuts to the manufacturer’s specifications.
appearance near the center bushing, which is 4. Position a jack on the spring and saddle so that
considered normal. the assembly sits in the front and rear spring
5. Once the cross tubes are separated, remove the mounting brackets, and align the spring eye
saddle assemblies, springs, or cushions. with the spring pin bore in the front bracket.
6. The spring and saddle assembly must be sup- 5. Install the spring pin while aligning the draw
ported on a floor jack and safety stand before key slot in the pin with the draw key bore in
the spring-aligned set screws can be loosened. the bracket, install the draw key, lock washer,
Next, remove the spring top saddle bolts and and nut, and torque up to manufacturer’s
nuts. The top pad can now be removed safely. specifications.
Lower the floor jack to remove the saddle. 6. Replace the zerk grease fitting in the spring pin
7. To remove the spring assembly, place the and grease with the recommended lubricant.
floor jack under the spring and loosen the
Solid Rubber Equalizer Beam
Disassembly
Courtesy of International Truck and Engine Corporation

1. Begin by removing the four drive pin bushing

retainer caps (refer to Figure 18-34) before re-
moving the drive pin nuts.
2. Next, remove the load cushions and saddle from
the vertical drive pins. The drive pin nuts may
need to be cut to facilitate removal. Depending
on the difficulty of the removal, it may be
necessary to replace the drive pin bushing.
3. Remove the torque rods from the cross member
Figure 18-34 Exploded view of a three-piece adapter frame bracket and install the new spring, cush-
bolt-type beam end mounting. ion, and saddle assemblies.

Copyright 2013 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part.
516 Chapter 18

Solid Rubber Equalizer Beam the sleeve. Now, install the other equalizer
Assembly beam into the cross tube and locate the beam in
the spring saddle.
1. Assemble the drive pin bushings to the saddle
2. At this point, the axle assemblies can be posi-
and install the bearing caps in place before in-
tioned under the center of the saddle; make sure
stalling the rubber load cushions on the saddle.
that the outer bushings are positioned in such a
2. Lubricate the drive pins with multipurpose
way that they line up with the center of the
grease on the frame brackets, before assembling
saddle legs. The frame can now be lowered
the frame brackets to the saddle. Install the
carefully. Ensure that the saddles center on the
drive pin nuts and washers with the flanges
beam end bushings. Install the saddle caps and
facing down and tighten them snugly. If the
nuts. Do not apply the final torque until the
frame hangers have been removed, the nuts
torque rods are installed and the equalizer
must be torqued to the manufacturer’s specifi-
beams are level with the frame.
cations after they have been assembled to the
3. Make sure that the cross shaft is free to float in
chassis frame.
the bushing assemblies on each side; this en-
3. Install the preassembled saddles, load cushions,
sures correct alignment of the left and right
and frame hangers to the chassis frame, and
equalizer beams.
install the mounting bolts, lock washers, and
4. Torque the saddle caps to ensure that the sleeve
nuts in place. Torque the mounting bolts to the
is secure to the bushing. This tightening pro-
manufacturer’s specifications before torquing
cedure has no effect on the pivot of the cross
the drive pin nuts.
shaft.
5. Connect the torque rods to the axle brackets and
Cross Shaft Installation the frame brackets. During the torque sequence,
tap the bracket with a hammer to seat the ta-
pered torque rod stud into the bracket. If the
Note: This procedure applies to both the leaf- torque rod ends have straddle mounts with two
spring and rubber spring equalizer beam suspen- holes, as shown in Figure 18-35, a spacer is
sions. The final torque values on the mounting required between the bracket and cross member
nuts should not be applied until the wheels have to get the correct axle adjustment. Once these
been installed and lowered to the ground. steps are complete, torque the shaft nuts and
equalizer beam end fittings to the manu-
1. Before inserting the bushing adapters, align the facturer’s specifications.
beam end bushing with the hanger brackets. 6. Reinstall the axle shafts in their original loca-
Lubricate the adapters with multipurpose tions. Reconnect the brake lines, drive shafts,
grease, and place the flat surface of each adapter and hardware removed during the disassembly
in the vertical position. procedure.
2. With a hammer, lightly tap the adapters into the
bushing until the adapter flanges seat against the
outer face of the hanger brackets. Install the bolt
and locknut in place. Do not torque up to Bracket
specifications yet. When installing rubber
bushed equalizing beams to the axles and sad- Torque
Courtesy of International Truck and Engine Corporation

dles, do not tighten the nuts until the torque rods Nut rod
are installed and the equalizer beams are level
with the frame. This reduces the chance of
creating torsional windup in the suspension.
Shaft and
bushing
Shaft
Reinstalling Equalizing Beam
Suspension Assemblies
1. One end of the cross tube must be positioned Bushing
into one end of the center sleeve of the equalizer
beam. Ensure that the tube seats correctly into Figure 18-35 Exploded view of a torque rod assembly.

Copyright 2013 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part.
Suspension Systems 517

ONLINE TASKS Shop Tasks

1. Use an Internet search engine to research the 1. Select a piece of equipment in your shop and
configuration of a typical off-road suspension identify the components in the suspension system
system. Identify a piece of equipment in your assembly. Inspect the suspension components to
particular location, paying close attention to the determine whether they are excessively worn or
suspension system design and arrangement, and damaged.
identify whether it has automated ride height 2. Select a piece of off-road equipment in your
compensation ability. Outline the reasoning shop that uses a conventional spring suspension
behind the manufacturer’s choice of design for system and identify the type and model of the
this application. equipment. List the major components and note
2. Check out this URL: [Link] the corresponding part numbers of the major
products/suspensions/[Link] for more in- suspension system components. Identify and use
formation on suspension system configuration the correct parts book for this task.
and design.

Summary
n An off-road suspension system’s primary purpose is n Nitrogen gas is the only gas that should be used to
to support the total weight of the equipment. charge suspension cylinders.
n An LHD (Load Haul Dump) consists of a drive axle n Pressurized oil and escaping nitrogen gas can pose a
mounted directly to the frame with only the tires to safety hazard to anyone who comes in contact with
absorb ground impact. either one.
n Unsprung weight is the total weight of those com- n Be sure that the charge valves are fully closed be-
ponents supported below the spring: this usually fore connecting the nitrogen charge lines to the
consists of the axle, brake hardware, and suspension suspension.
components. n Suspension dimensions can be affected by temper-
n Sprung weight is defined as the load that the sus- ature differences between the adjustment location
pension must support during normal operation. and the operating location.
n Nitrogen in suspension cylinders must be dis- n Tandem drive applications that are used on articu-
charged before checking the oil level. Never remove lating haulage trucks often use equalizing beam
any plugs or valves from a suspension cylinder if suspension systems.
the rod is not fully retracted. n Equalizing beam suspensions allow the machine
n Large haulage trucks use a gas/suspension cylinder load to be equally distributed between the axles
at each front wheel end instead of a conventional while compensating for road irregularities.
kingpin as part of the steering linkage. n Caution should be exercised whenever replacing
n A key advantage of independent gas/hydraulic sus- suspension springs. Multi-leaf spring packs are un-
pension systems is their simplicity of design and der massive tension and can cause serious injury if
ability to absorb changing load and road conditions. not handled properly.
n The pressures in each suspension cylinder can be n If a hydraulic leak is suspected, never run your hands
affected by changes in ride height due to leaks at over the lines to locate the leak. A high-pressure leak
opposite ends of the equipment. can penetrate the skin.

Review Questions
1. Which of the following describes the term unsprung weight?
A. the total weight of the components C. the total weight of the equipment
not supported by the spring D. the rebound rate of the equipment
B. the total weight of each end of an axle

Copyright 2013 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part.
518 Chapter 18

2. Which symptom would result from a broken spring pack center bolt?
A. erratic steering C. bouncing front end
B. U-bolt failure D. broken leaf spring

3. If you determine that a spring pack has a single cracked leaf, what is the recommended repair procedure that
should be performed?
A. Replace the spring pack. C. If the crack is small, weld it.
B. Disassemble the spring pack and D. Do nothing; it’s only a crack.
replace the broken leaf.

4. While lubricating a spring pack assembly, one spring pin will not take grease. Which of the following should
be done first?
A. Change the grease fitting on the C. Remove the weight from the spring and attempt to
bracket spring pin. grease again.
B. Replace the bracket spring pin. D. Heat it up with a torch to unplug the grease passage.

5. How are the springs loaded in a spring pack under tension?

A. U-bolts C. spring pins
B. center bolt D. torque rod

6. What term is used to describe the most compressed condition of a suspension spring?
A. jounce C. deflection rate
B. rebound D. unsprung load

7. What purpose does a torque arm serve on a suspension system?

A. controls axle torque C. controls jounce
B. controls rebound rates D. controls the suspension height

8. Which term describes an equalizing-beam suspension?

A. torsion bar C. air spring
B. walking beam D. multi-leaf variable rate

9. Which of the following functions can be performed by torque rods?

A. dampen axle windup caused by C. dampen axle twist under braking
driveline torque D. all of the above
B. align axles

10. What do large quarry trucks often use in the front suspension to replace a kingpin?
A. suspension cylinder C. coil spring
B. torque rods D. leaf spring

11. How are rear cylinder barrels connected to the equipment frame on a large quarry truck?
A. torque rod C. cylinder stem
B. kingpin D. spring pin

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Suspension Systems 519

12. Where does the adjustable ride control on a haulage truck get its oil supply?
A. from the brake or hydraulic C. It’s a closed system, and does not need an external
circuit supply source.
B. an independent hydraulic system D. none of the above

13. What will occur if one cylinder develops a gas leak in a suspension cylinder on a haulage truck with an
independent gas-charged system?
A. It would not affect the other three C. The pressure would rise in the remaining three
suspension cylinders. cylinders.
B. All suspension cylinders would D. The truck’s ride height would be affected.
experience a pressure drop.

14. When charging a suspension cylinder with nitrogen, what procedure must be observed?
A. Compensate for temperature if C. Support the equipment to keep it level.
required. D. Take the weight off the suspension cylinder.
B. Drain the oil from the cylinder first.

15. What step must be observed first when installing a new accumulator on the ride control system?
A. Fill the accumulator with oil. C. Check the pressure in the accumulator.
B. Purge the accumulator of all air. D. Hydraulic pressure must be present to charge properly.

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