SRT95 Off-Highway Truck

Suspension System
Part1 Overview
Part2 Removal and Installation
Part3 Disassembly and Assembly
Part4 Charging Suspension Cylinder
Part5 Inspection and Maintenance
Part1 Overview
 The suspension system supports the weight of the machine as the elastic device
between the frame and the axle , and absorbs the shock from uneven road surfaces
to provide a comfortable ride for the operator. At the same time, it maintains the
stability of the machine by ensuring that all four wheels are always in contact with
the ground surface.

Suspension system

Front suspension Rear suspension

MacPherson independent Non-independent

suspension suspension
 1.1 Front Suspension System
 The front suspension uses MacPherson independent suspension mode.

Front suspension cylinder

Frame

Spindle

Steering arm

A-arm
Front suspension
1.2 Rear Suspension System
 Rear suspension cylinder is an elastic device suspending to the rear part of
truck. It is installed to the rear part of each longitudinal beam of frame, under
the body and above rear axle.

Link

Frame

Pin

Rear suspension
cylinder

Pin

Rear axle
Rear suspension
1.3 Suspension Cylinder

Hydropneumatic cylinder with nitrogen and oil

 Elastic medium ——Nitrogen
 Load transfer medium——Oil

This acts as a shock absorber (spring and

damper) by contracting and expanding the
nitrogen gas and oil to absorb the load from the
road surface.

Front Rear
1.3.1 Front suspension cylinder

Front axle Wear ring Buffer stopper Seals& Wear ring Dust boot

Bearing

Piston rod
Piston Orifice&ball Cylinder tube Guide sleeve
 1.3.2 Rear suspension cylinder

Seals& Wear ring Orifice&ball Wear ring

Bearing Piston rod Dust boot Guide sleeve Piston Cylinder tube Bearing
Part 2 Removal and Installation

WARNING
1 、 To prevent personal injury and property loss, be sure
blocking and lifting equipment is of sufficient capacity and
properly secured to do the job safely.

2 、 Suspension cylinder is charged with high-pressure nitrogen

gas, ensure that the gas pressure in the cylinder is completely
released before the suspension is dismantled.

3 、 Release pressure as described under 'Relieving Cylinder

Pressure' before removing valves or fittings. Accidental release
of pressure will result in personal injury and property damage.
Part 2 Removal and Installation

2.1 Removal (front suspension)

1 ） Position the truck in a level Pin

work area, apply the parking brake
and switch off the engine.
2 ） Turn the steering wheel in
both directions several times to
relieve pressure in the steering
system. Block all road wheels.

3 ） Relieve nitrogen pressure

from both front suspension
cylinders.

4 ） Jack frame up at “horse collar” Pin

until front suspension cylinder is
fully extended. Pin A-arm
2.1 Removal (front suspension)
5 ） Jack up front suspension cylinder until
tire is off ground and block steering arm in
position.
Pin
6 ） Remove front tire and rim.

7 ） Remove steering tie rod and steering

cylinder from steering arm.

8 ） Position lift truck forks under front

suspension cylinder and block up front
suspension cylinder.
9 ） Remove pin assembly which secure
front suspension cylinder to steering arm ；
10) Remove the front suspension cylinder,
Pin
A-arm and steering arm to a suitable work
area for further disassembly. Pin A-arm
2.2 Installation (front suspension)
1 ） Place cushion block on the fork of fork
truck as shown in the picture. Then locate
the front suspension cylinder assembly in
the installation position on frame.

2 ） Secure front suspension cylinder to frame

with three pin assembly. After pins are
installed, use bolts and washers to lock
them.

3 ） Move away the installation equipment.

4 ） Connect brake hydraulic pipeline to brake

calipers and exhaust the brake system.

5 ） Install front tire and rim assembly.

1. Front suspension cylinder
6 ） Charge the suspension cylinder according 2. Wooden blocking
to the 'charging instructions’. 3. Lift truck forks
2.3 Removal (rear suspension)

1 ） Position the truck in a level work

area, apply the parking brake and
switch off the engine. Bolt &
2 ） Turn the steering wheel in both washer
directions several times to release
pressure in the steering system. Pin
Block all road wheels.
3 ） Place a 35 mm spacer between the
frame and oscillation stop on both
sides. Pin

4 ） Release nitrogen pressure from Bolt &

both rear suspension cylinders. washer
Refer to 'Release Cylinder
Pressure‘.
2.3 Removal (rear suspension)
5 ） Support the suspension with sufficient
force before remove the pin.

6 ） Remove bolt and washer securing pin Bolt &

assembly through lower end of washer
suspension cylinder and rear axle
housing brackets. Drive pin assembly Pin
out.

7 ） Remove bolt and washer securing

pin assembly through upper end of Pin
cylinder and frame mounting. Drive
pin assembly out. Bolt &
washer
8 ） Remove the rear suspension cylinder,
move it to a clean working area for
further removal.
2.4 Installation (rear suspension)

1 ） Clean all parts surface of suspension

cylinder and frame to make them smooth.
Bolt &
2 ） Attach a suitable lifting device or a washer
‘come-along’ to suspension cylinder and
make sure the charge valve is outside the Pin
cylinder.

3 ） Apply anti-seeze lubricant to pin

assembly.
Pin
4 ） Insert pin through the rear axle housing Bolt &
and the pin hole of suspension cylinder, push
it to specified position, and fasten it to the washer
rear axle housing with washer and bolt.
2.4 Installation (rear suspension)
5 ） Install up side of suspension cylinder to
frame, insert pin through the frame and the pin
hole of suspension cylinder, push it to Bolt &
specified position, and fasten it to the frame washer
housing with washer and bolt.
Pin
6 ） Remove the lifting equipment or chain
from the rear suspension cylinder.

7 ） Follow Steps 1 through 6 to install the Pin

other cylinder.
Bolt &
8 ） Charge the suspension cylinder washer
according to charging procedure.
Part 3 Disassembly and Assembly
3.1 Disassembly (front suspension)
Front suspension cylinder
1 ） Remove A-arm ：
a. Remove the bolts and baffle of steering Key
Bearing
arm.
Bolt
b. Remove the A-arm.
c. Remove the bolts and baffles of A-arm to
separate the A-arm and bearing.
2 ） Remove steering arm: Steering arm
a. After the A-arm is removed, remove eight
Bearing
bolts to separate the steering arm from Bearing
suspension cylinder. Baffle of A-arm
b. Remove flat key in keyway of the steering Bolt
Baffle of steering arm
arm.
3 ） Remove the front suspension cylinder.
3.2 Disassembly (front suspension cylinder)

Front suspension cylinder

3.3 Disassembly (rear suspension cylinder)

Rear suspension cylinder

Part 4 Charging Suspension Cylinder

Plug ： oil fill port

A
L

Charge valve ：
Nitrogen charge port

Plug ： air exhaust

port
Front Rear
L:Check length of suspension cylinder, check oil level and Nitrogen charge level.
L=The distance between center of pin and end cap of guide sleeve.
 4.1 Relieve Cylinder Pressure
1 ） Truck must be empty and on a flat level surface prior to relieving ride
cylinder pressure.
2 ） Support the frame near the suspension with blocking and/or a
hydraulic jack with adequate capacity.
3 ） Remove the cap from nitrogen charging valve seat the top of the
cylinder. Turn the hex out on the valve 1/4 to 1/2
turn counter-clockwise and depress the
valve core. If no gas escapes, continue
to turn the hex nut in 1/4 turn increments
until the nitrogen releases as the valve
WARNNING
core is depressed. Pressurized cylinders. Release pressure
4 ） Remove blocking or release pressure as described below before removing
on the hydraulic jack and allow the truck’s valves or fittings. Accidental release of
weight to fully retract the suspension pressure will result in personal injury and
cylinder rod. property damage.
5 ） Depress nitrogen charging valve core
again to be sure all pressure has been relieved.
4.2 Filling Oil (Cylinder filled initially, or refilled during maintenance)

1 ） Position the truck in a level work area.

2 ） To detect oil level correctly, nitrogen must be completely discharged from the
cylinder body. This operation can be completed by evacuating gas or by sustaining
frame properly with cushion block to keep cylinder in the open state for more than 24
hours.
3 ） Jack frame up until suspension cylinder is fully extended. Secure the truck in this
position when the front and rear suspension cylinders are fully extended. The position
is shown in the picture: A=525mm(Front), A=517.5mm(Rear).
A=525 A=517.5

Front suspension cylinder Rear suspension cylinder

4 ） Remove the cap from nitrogen charging valve at the top of the cylinder. Turn the hex
out on the valve 1/4 to 1/2 turn counter-clockwise and depress the valve core to
release the nitrogen .
5 ） Slowly lower down the frame to make the dimension “D”(the distance between the
center of pin and end cap of guide sleeve) equal to the value shown in the follow
picture:D=205mm(Front ), D=348mm(Rear).
6 ） Release all residual gas pressure in the suspension cylinder.

D=205 D=348

Front suspension cylinder Rear suspension cylinder

7 ） Oil fill:
a. Oil fill should accord to the following procedure in order to exhaust the air of cylinder
and make the oil level correct.

b. Remove the plug in piston rod and plug in the cylinder tube assy. meanwhile the charge
valve should not be removed. Attach oil fill equipment to the plug port in piston rod and fill
the cylinder until oil flows free of air bubbles from plug port in the cylinder tube assy.

c. Reinstall plug in the port of cylinder tube assy. and remove nitrogen charging valve in
the ports of piston rod. Go on filling the cylinder with the plug port in the piston rod. Stop
oil filling until the oil flows free of air bubbles from charge valve port, and remove oil fill
equipment.

d. Reinstall plug and nitrogen charging valve in the ports.

 4.3 Charging Nitrogen

Pressure Gauge
Tank valve

Cylinder valve Cylinder adaptor

WARNING
Gland nut
Gland fitting Release pressure as described before
Bleeder valve removing valves or fittings. Accidental
Vlave chuck release of pressure will result in personal
injury and property damage.
Valve A high pressure nitrogen pressure
extension regulator must be used with the charging
Line
assembly. Failure to use a pressure
Nitrogen charging assembly regulator could cause property damage,
personal injury, or death.
1 ） Parking the truck in a level work area. The truck
must be parked stably without applying any brake.
2 ） Remove cover of the charge valve carefully because Charge valve
Charge valve
residual gas pressure may exist.
3 ） Attach the charging assembly kit to the nitrogen
bottle by turning down on gland nut.
4 ） Connect the charge component to charge valve on
suspension cylinder .
5 ） Open the valve on the nitrogen bottle slowly and
Nitrogen
note the reading on pressure gauge .The available
cylinder
pressure in nitrogen bottle must be over 5Mpa.
6 ） Turn small hex on nitrogen charging in the cylinder
two to three turns anticlockwise to unseat the valves Tee piece
internally; Rotate 'T' handles clockwise until they
seat, opening check valves (valve cores) in nitrogen
charging valves; Charge both cylinders to correct Charge of suspension cylinder
height and pressure, by opening tank valve slowly
and closing it occasionally. To check pressures in the
cylinders, close tank valve and note the reading on
pressure gauge.
7 ） The cylinder should be charged to the height ‘B’ shown in the picture and MUST NOT
be over charged above the recommended height. Overcharging can cause the piston rod
to over extend, thus damaging the piston retaining bolts.
8 ） When correct height ”B”( Front: B=410mm; Rear: B=455mm) has been reached, close
the valve on nitrogen bottle and tank valve securely. Turn small hex on nitrogen charging
valves clockwise to close valves internally. Rotate 'T' handles of valve chucks
anticlockwise until they stop.

B=410 B=455

Front Rear
9 ） With cylinder valve open and tank valve closed, bleed pressure gauge and hoses
through bleeder valve. Loosen the swivel nuts and remove valve chucks and
hoses from nitrogen charging valves.
10 ） Check nitrogen charging valves for leakage with soapy water. If either core is
leaking, depress it quickly once or twice to reseat the core. If leakage persists,
replace core. Tighten charging valve lock nut (The torque is 50N·m ), and replace
valve cap. Tighten valve cap （ The torque is 4.5 ～ 5.5N·m ） so that it cannot
be removed by hand.
11 ） Run the mining truck about 24 hours, perform the procedure of inspect un-load
height again, and make adjustment if necessary.
Note 1 ： In case of any leakage in the spool of charge valve:
a ） Check the torque of spool. The torque should be 0.35 - 0.45N•m.
b ） If the leakage cannot be stopped, check the spool for damage or contamination.
Replace it if necessary.
Note 2 ： On new or rebuilt cylinders, the seals and wipers may grip the piston rods
tighter and make it difficult to obtain the correct height. If this happens, the
cylinders should be charged as accurately as possible, the truck operated for
several days, and then the cylinder re-checked.
Note 3 ： If the cylinders bottom out when they are charged to the correct height and
the truck is not being overloaded, the oil level may be incorrect. The cylinders
should be discharged, refilled with oil, and recharged as described above.

WARNING
Use dry nitrogen to charge cylinder. Do not use a gas
such as oxygen which ,if used by mistake for
pressurizing, will explode violently when coming into
contact with oil or grease.
Part 5 Inspection and Maintenance
5.1 Maintenance and Adjustment
Periodic maintenance includes the following steps ：
1 ） Clean the device. Check the wear, damage or oil-gas leakage. Pay special
attention to the exposed part of piston rod and inflation valve. Repair or replace
them as required.
2 ） Check all parts for wear or looseness. In case of any looseness, repair
or replace them if necessary.
3 ） Inspect the exterior of suspension cylinder for signs of oil leakage. Repair or
replace according to the requirements and add oil again according to the method
described in the instructions. The following signs indicate that it is necessary to
maintain the interior of suspension:
a. There is oil leakage in the surrounding of suspension cylinder.
b. The gas column height changes frequently.
5.2 Inspection

1 ） Wash all parts thoroughly in a suitable solvent. Dry all parts with compressed air.
Check all inner and outer grooves in guide sleeve and piston for cleanliness.
2 ） Inspect cylinder tube assy. , piston rod and piston for scores, scuffing or small
ridges in the walls. Use a fine stone to smooth out any defective areas. If damage
is too extensive, replace with a new part.
3 ） Check all cylinder assembly components for signs of unusual distortion or
excessive wear. Replace defective components.
4 ） Inspect all plugs, balls and charging valve . Check their seating positions in
piston rod and cylinder tube assy. If threads in any of these parts are damaged,
restore the threads. If threads are not repairable, the defective part must be
replaced.
5 ） Inspect wear ring and bearing of the rear suspension cylinder for excessive wear
or damage. Replace them if is damaged.
6 ） Inspect wear ring and bearing of the front suspension cylinder for excessive wear
or damage. Replace them if is damaged.
Thanks!