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EML STANDARD
CLASSIFICATION : SCOPE OF APPLICATION : STANDARD No.

ENGINEERING STANDARD
ISSUED BY :

EICHER MOTORS LIMITED ES-VE-002

TITLE :

SUSPENSION INSTALLATION

PAGE

PDD 1.0 Scope :

DATE OF ISSUE :

This standard covers the General, Technical & Dimensional specification of suspension Installation.

2.0 General specification :

2.1 Spring must be installed as the military wrapper in forward. 2.2 Spring must be displayed in un laden condition. 2.3 Pin should not be hammered hard during installation. 2.4 Insert spring pin from outside such that thread for grease nipple is outward and the slot for lock bolt is down ward. 2.5 Spring combination +/- to be maintained. 2.6 Amount of grease to be mentioned

3.0 Component positioning in suspension system :

3.1 Bump Stopper: Bump stopper position & stiffness of bump stopper to be designed in such a way 3.1.1 Front: The travel of spring to be restricted at 2.36g max 1g load= (Laden FAW-Un sprung mass)/2 The spring should touch to bump stopper at 2.1g load. The bump stopper should get fully compressed after 2.36g Load. 3.1.2 Rear: The travel of spring to be restricted to 3.1g max The spring should touch to bump stopper at 2.9 g load The bump stopper should get fully compressed after 3.1 g Load. 3.1.3 Vehicle static deflection and ride clearances with various types application Static Deflection : Static deflection of spring is equal to static load divided by static spring rate.( Deflection from free camber to rated load) Ride Clearance : The distance between spring top to bump stopper bottom surface. In other wards we can say the distance up to which the spring can travel. ( from rated load to max designed load) ( Refer table 1.1 for limit value)

REV

E.O. No

REVISION

PAGES

DATE

CHKD

Approved by V.MULCHANDANI

Checked by

Prepared by S.K.BHANJA

N. GOEL

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Table: 1.1 Passenger Automobiles ( at design load) Trucks ( at design load) For High way operation For off road operation Static deflection (mm) 100~300 75~200 25~175 Ride Clearance (mm) 75~125 75~125 50~125

3.2 Shock absorber: a. Maximum opening length of shock absorber to be at least 10mm more than the distance between shock absorber top & bottom mtg. bracket at max rebound condition after worst condition tolerance stack up. b. Compressed length of shock absorber to be at least 10mm less than the distance between shock absorber top & bottom mtg. bracket in metal to metal condition after worst condition tolerance stack up. c. Damping force at 1.5m/sec to be taken into consideration during analysis of shock absorber mtg. bracket. d. Refer standard JASO-602 for shock absorber alignment & mounting details. 3.3 U bolt: a. U bolt should come out min 10mm in maximum material condition & max 30mm at minimum material condition. 3.4 Wear plate: a. Clearance (suspension hanger, leaf spring & wear plate) in maximum material condition should not be less than 0.8mm. b. Clearance (suspension hanger, leaf spring & wear plate) in minimum material condition should not be more than 2mm. 3.5 Shackle : a. Shackle length should be 5% to 10% of spring span.( as per spring design Manual chapter 6) b. Shackle angle during un laden condition should be +/-7 degree.

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3.6 Caster Angle a. Suspension mtg. brackets should be designed such a way that the in built caster angle should be 2.5 degree, caster plate can be added need basis. 3.7 Pinion Angle a. Suspension mtg. brackets & shackle to be placed in such a way that designed such a way that the in built caster angle should be 2.5 degree, caster plate can be added need basis. 3.8 Helper spring a. Helper spring length should be fixed such a way that the spring should come out of helper bracket to avoid digging.

4.0 Ride Characteristics a. The front suspension should have 30% lower ride rate (natural frequency) than rear suspension. b. The pitch and bounce frequencies should be closer together around 1.5Hz c. Natural frequency in case of air suspension: Passenger bus: Cargo: 1.2Hz ~1.5Hz 1.5Hz ~2.0 Hz 2Hz ~2.5 Hz

d. Roll angle: Roll angle should be less than 6 degree assuming vehicle speed 40km/hr & turning radius of road 50000mm.

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