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Specifications
Specifications ................................................................................................................................ 204-00-2
Descriptions and Operations
Suspension System ....................................................................................................................... 204-00-4
Diagnosis and Testing
Suspension System ....................................................................................................................... 204-00-6
General Procedures
Adjustment of Cater Angle ........................................................................................................... 204-00-20
Adjustment of Camber Angle ....................................................................................................... 204-00-21
Inspection of Sideslip Rotation .................................................................................................... 204-00-23
Inspection and Adjustment of Toe-in............................................................................................ 204-00-24
Inspection of Vehicle Camber Height .......................................................................................... 204-00-26
Inspection and Adjustment of Vehicle Height .............................................................................. 204-00-27
2009.06 Boomday
204-00-2 Suspension System – General Information 204-00-2
Specifications
Location Parameters
Item Specification
Toe-in of front wheel
2WD 0 ~ 4 mm
4WD 0 ~ 4 mm
Camber angle of front wheel
2WD 0°30' ± 60'
4WD 0°30' ± 60'
Difference between those of left and right wheels 0°23 ± 23'
Cater angle of kingpin
2WD 1°50 ' ± 45'
4WD 2°10' ± 45'
Difference between those of left and right wheels 0°18' ± 18'
Inclination angle of kingpin
2WD 10° ± 60'
4WD 10° ± 60'
Parameter Specification
Item Specification
Vehicle height (height from ground to sharp corner of wing plate)
215/70R15C (2WD)
2007 style 655 mm
2009 style 800 mm
LT215/75R15
2007 style 675 mm
2009 style 780 mm
Camber height
2WD 56 mm
4WD 130 mm
2009.06 Boomday
204-00-3 Suspension System – General Information 204-00-3
Specifications
Torque Parameters
Item Nm
Pretightening force of upper swing arm ball joint 2.2 ± 1.2
Pretightening force of lower swing arm ball joint 2 ± 1.5
Adjusting locking nut of thrusting rod 130 ± 13
Locking nut on steering tie rod 100 ± 10
Connecting bolt of upper swing arm support pin and support (2WD) 110 ± 15
Connecting bolt of upper swing arm support pin and support (4WD) 155 ± 15
2009.06 Boomday
204-00-4 Suspension System – General Information 204-00-4
Descriptions and Operations
Suspension System
Adjustment of wheel angle Negative toe-in (toe-out)
Theoretical adjustment angles of kingpin ca-
ter angle and wheel camber angle shall be
determined by the vehicle manufacturer. Correct
the kingpin cater angle / wheel camber angle
with an adjuster to make it conform to the
specifications. However, before correcting the
kingpin cater angle / wheel camber angle, check
thoroughly whether suspension system is aged or
damaged, so as to avoid any change caused by
the adjustment of equipment.
Camber angle of wheel
2009.06 Boomday
204-00-5 Suspension System – General Information 204-00-5
Descriptions and Operations
Terminology
Light shock
Light shock is sometimes confused with flutter,
which is caused by the unbalance of tires or
steering wheel. The drive may feel slight rotary
flutter of steering wheel.
Run-out / drift
Run-out / drift is a tractive feeling of hands on
steering wheel, which must overcome this force to
keep the stability of vehicle driving.
Drift / run-out is a response produced by the
vehicle when the hands of driver depart the
steering wheel.
● Run-out / drift related to vehicle driving will
cause continual drifts in linear driving of vehicle
when it drives on a flat road, which is required to
eliminate through continual steering inputs.
● External conditions acting on the vehicle, e.g.
wind force and crowned road surface, can
cause run-out / drift.
2009.06 Boomday
204-00-6 Suspension System – General Information 204-00-6
Diagnosis and Testing
Suspension System
Inspection and Confirmation
1. Road test
The road test on the flat road surface is used to
confirm the faults provided by the customers.
2. Tire check
● Check the pressures of tires and inflation pr-
essures of cold tires under all the normal
loading conditions.
● Check whether all the tire dimensions conform
to the specified values.
● Check the tires for abnormal wears and
damages.
3. Check of chassis and lower bodywork
Remove all the slurry, dust and road surface de-
posits, etc from the chassis and lower bodywork.
4. Check the attached configuration after
selling the vehicle.
Check the changes of steering system, susp-
ension system, wheels and tires or other
configurations after selling the vehicle.
Appearance check list
Mechanical
● Torsion bar or height adjusting arm
● Lateral stabilizer rod
● Shock absorber
● Rubber bushing
● Steering knuckle
● Lower/upper swing arm ball joint sheath
● Front wheel bearing
● Oil seal
● Steel plate spring unit
● Clip
● U-shape bolt
● Loosening or damage of front or rear sus-
pension assembly bolt
5. Solve the problems found out before the
next check.
6. In case of not confirming the causes from
the appearance, first confirm the symptoms,
and then check as per the list of symptoms.
2009.06 Boomday
204-00-7 Suspension System – General Information 204-00-7
Diagnosis and Testing
Symptom List
2009.06 Boomday
204-00-8 Suspension System – General Information 204-00-8
Diagnosis and Testing
2009.06 Boomday
204-00-9 Suspension System – General Information 204-00-9
Diagnosis and Testing
Accuracy Test
Accuracy test A: Flutter and swing of steering wheel
2009.06 Boomday
204-00-10 Suspension System – General Information 204-00-10
Diagnosis and Testing
2009.06 Boomday
204-00-11 Suspension System – General Information 204-00-11
Diagnosis and Testing
2009.06 Boomday
204-00-12 Suspension System – General Information 204-00-12
Diagnosis and Testing
2009.06 Boomday
204-00-13 Suspension System – General Information 204-00-13
Diagnosis and Testing
2009.06 Boomday
204-00-14 Suspension System – General Information 204-00-14
Diagnosis and Testing
2009.06 Boomday
204-00-15 Suspension System – General Information 204-00-15
Diagnosis and Testing
2009.06 Boomday
204-00-16 Suspension System – General Information 204-00-16
Diagnosis and Testing
2009.06 Boomday
204-00-17 Suspension System – General Information 204-00-17
Diagnosis and Testing
2009.06 Boomday
204-00-18 Suspension System – General Information 204-00-18
Diagnosis and Testing
Parts Testing
Shock Absorber ● Lower swing arm ball joint: 2 ± 1.5 Nm.
2009.06 Boomday
204-00-19 Suspension System – General Information 204-00-19
Diagnosis and Testing
2009.06 Boomday
204-00-20 Suspension System – General Information 204-00-20
General Procedures
Item Description
1 Upper swing arm support
2 Shim
2. Remove the bolt.
4. Check the cater angle.
ATTENTION: The difference between
those of both wheels shall be within 35'.
2009.06 Boomday
204-00-21 Suspension System – General Information 204-00-21
General Procedures
Item Description
1 Shim
2 Upper swing arm support
2009.06 Boomday
204-00-22 Suspension System – General Information 204-00-22
General Procedures
2009.06 Boomday
204-00-23 Suspension System – General Information 204-00-23
General Procedures
2009.06 Boomday
204-00-24 Suspension System – General Information 204-00-24
General Procedures
2009.06 Boomday
204-00-25 Suspension System – General Information 204-00-25
General Procedures
2009.06 Boomday
204-00-26 Suspension System – General Information 204-00-26
General Procedures
Item Description
Center of lower swing arm and
1
cross beam connecting hole
Center of lower swing arm ball
2
joint lower end
3 Horizontal plane
● 4WD vehicle
2009.06 Boomday
204-00-27 Suspension System – General Information 204-00-27
General Procedures
Item Description
1 Sharp corner of right wing
2 Sharp corner of left wing
3 Horizontal plane
Adjustment
All the vehicles
1. Check and make up the tire pressure.
2. Park the vehicle on the horizontal plane.
3. Front and rear suspensions stay at normal
operation state.
Rear-wheel driving vehicle
4. Loosen the locking nut of torsion bar front end.
● During the installation, tighten it up to 130 ±13 Nm.
All the vehicles
2009.06 Boomday