Suspension

Page 1 (01/08) Media # CTMDT9361 860E AC

Rear Suspension, Rod down style
Rear suspension pin and clevis mount
Variable rate hydro-pneumatic with
integral rebound control, 12” Rod dia
Maximum stroke 11.5” (291 mm)
Glass filled Nylon Bearings

Page 2 (01/08) Media # CTMDT9361 860E AC

Front Suspension

Forged front suspension rod, 15” dia

Large casting steel mounts
Extra-length Glass filled Nylon Bearings
Maximum front stroke 12.9” (330 mm)

Page 3 (01/08) Media # CTMDT9361 860E AC

Front Suspension, mounting

Mounting faces must be

clean & flat to within
0.25mm

Install Shear keys flush

with end of slot

Use “turn of nut” method

Replace after EACH use

Lubricate threads and

washer faces with multi
purpose 3% Moly grease

Do not exceed rotational

speeds of 4 RPM.

Page 4 (01/08) Media # CTMDT9361 860E AC

Front Suspension, Torque procedure

Torque all 14 capscrew’s by following the

illustrated sequence and maintain 1000 ft.lbs.
up until the final preload steps
All fasteners must be individually
loosened, then preloaded one at a time,
in sequence, and according to the chart
below, whilst maintaining the initial
clamping torque on all adjacent bolts

Page 5 (01/08) Media # CTMDT9361 860E AC

Front Suspension Inspections
Ensure that the opposite end of each
capscrew DOES NOT TURN during the
tightening process

In service inspections of all fasteners and

joints should be performed during the
initial 8, 50, 250 and 500 hours of work.
Index marks should be made on all
fasteners and structures to facilitate this
inspection.

If any fastener or joint displays signs of

movement, the fasteners must be removed,
inspected and re-tightened

Page 6 (01/08) Media # CTMDT9361 860E AC

Front Suspension, Bolt Torque principles

Precise stretch

Lubricate threads

Accurate pre-torque

Page 7 (01/08) Media # CTMDT9361 860E AC

860E Electric Drive Truck

Page 8 (01/08) Media # CTMDT9361 860E AC

Hydrair II Suspension

Page 9 (01/08) Media # CTMDT9361 860E AC

Hydrair II Suspension

Rod entry = < volume

= > pressure

Re-bound control provided by control of Annulus area oil

Dirt Ring, indicates operating stroke of assembly

Page 10 (01/08) Media # CTMDT9361 860E AC

Boyles Law……… (P1 V1 = P2 V2)

Page 11 (01/08) Media # CTMDT9361 860E AC

Hydrair II Principle

The heavier the load, the

greater the pressure

P = F
A

Page 12 (01/08) Media # CTMDT9361 860E AC

860E Electric Drive Truck Boyles Law at Work

Page 13 (01/08) Media # CTMDT9361 860E AC

860E Electric Drive Truck

Page 14 (01/08) Media # CTMDT9361 860E AC

Hydrair II Suspension

Page 15 (01/08) Media # CTMDT9361 860E AC

Suspension charging, Equipment
Bleed off trapped
gas

Secondary seat

Primary seat

Page 16 (01/08) Media # CTMDT9361 860E AC

Front Suspension Oiling and Gassing

• Bleed nitrogen pressure with charge kit

• Drain old Oil, re-fill and set oiling height

• Carry out on both sides simultaneously

Page 17 (01/08) Media # CTMDT9361 860E AC

Rear Suspension charging

Page 18 (01/08) Media # CTMDT9361 860E AC

Rear Suspension, flushing & oiling

Support truck at oil height

Bleed off all nitrogen

Remove Drain plug

Remove Charge valve and fill from below

(this exhaust’s all aerated & dirty oil to avoid standing time)

Page 19 (01/08) Media # CTMDT9361 860E AC

Rear Suspension, Flushing
FLUSHING Routine (yearly) operation

Preserves internal
components

Saves time when servicing

oil levels

Used Suspension oil, +/- 6000hrs

Page 20 (01/08) Media # CTMDT9361 860E AC
Rear Suspension, Correct Oil Level

OILING

Page 21 (01/08) Media # CTMDT9361 860E AC

Rear Suspension, Gas Level

Hoist body to move more

EMPTY mass onto rear axle
TRUCK

Page 22 (01/08) Media # CTMDT9361 860E AC

Rear Suspension, Results when Blocks are removed

EMPTY
TRUCK
EMPTY
TRUCK

F=PxA

Page 23 (01/08) Media # CTMDT9361 860E AC

Rear Suspension, Blocks removed cont.

EMPTY
TRUCK

Page 24 (01/08) Media # CTMDT9361 860E AC

860E Electric Drive Truck

Page 25 (01/08) Media # CTMDT9361 860E AC

 End of Suspension section

Page 26 (01/08) Media # CTMDT9361 860E AC

860E Electric Drive Truck Improvised Tool

Page 27 (01/08) Media # CTMDT9361 860E AC