Do-it-yourself Kamaz with air suspension

AIR SUSPENSIONS AIR SUSPENSION FOR KAMAZ 43118 We implemented the idea with air springs for the KAMAZ 43118 saiga * purchased 2 air bags from a trailer for lifting the axle 3500 per piece * fitting for a 12 mm tube * output pressure limiting reducer to 12 mm 780 per piece * ball valve in the air supply line 12 mm *tee 12 mm *plastic hose 12 mm 10 meters

The work included making 15 mm metal transition pads for the cushions, moving the bumpers, drilling holes in the frame for the second bolt for fastening the pads, and cutting eyes for the desired cushion pad.

Due to the heavy weight of the CMU, the front springs sagged over the year of operation and airbags had to be installed. Before the alteration, the distance to the selector was 2-3 cm and when driving, even on a flat road, it shook as if the bridges were bolted to the frame.

After installing the airbags, the car became higher and, at a pressure in the airbags of 5-6 atmospheres, it rises 10-15 cm higher than before and the front axle springs bend almost like a chassis without a power steering unit and an internal combustion engine. On my first ride I felt a colossal difference in the smoothness of the ride. It drives smoothly, like a premium truck!

If you compare the softness of the ride from 0 to 10, before the modification it was 1, but now it’s 10+

The whole alteration came out cheaper than the cost of one pack of springs for this car.

This modification was put to the test on September 19, 2018, and we will test the survivability of this idea.

In the future I plan to install the same pillows on Mazda Titan gp. 3 t.

Part 1. Kamaz on air cushions

KamAZ 55111 air suspension

Air suspension mounting. Install air suspension. Assembling the lower mount

Kamaz pneumatic 2 regulator operation

the whole truth about air bags on Kamaz

Purpose, device and principle of operation

The suspension design includes elements such as:

Electronic type sensor for acceleration. This device makes it possible to track the level of body tilt, its position relative to the road and acceleration.
Compressor. It is necessary to supply compressed air flows to the receiver.
Front and rear rack. With its help, the ground clearance is adjusted. This can be done either automatically or manually.
Receiver and balancing device bracket. Adapts the operation of suspensions and facilitates the connection of all elements of the suspension mechanism.
Control block. It is necessary for correct processing of sensor signals.

Air suspension is required for:

ground clearance adjustment;
transport alignment;
improving truck handling and stability.

The body level is maintained regardless of the vehicle load. Sensors continuously measure the distance of the wheels to the body part. At critical values, the valves of the lifting mechanism and the release valve are activated to lower the suspension mechanism.
When the body height level changes, the speed of the suspension changes. The smoothness of the truck is analyzed and the height of the body is adjusted to suit the unevenness of the road surface.

How to make it yourself

In order to make a pendant with your own hands, you will need:

grinder and stepladder;
metal brush;
hammer;
compressor;
knife;
air cushions and struts included;
2 solenoid valves;
pressure gauge;
PVC pipes;
sealant.

Front

Front suspension manufacturing procedure:

Knock the cap off the stand and cut off the paint layer using a grinder.
Press the adapter onto the stand.
Attach spacer rings to the transition mechanism. This will help improve the smoothness of the vehicle.
Connect small-diameter plastic tubes to the air flow openings.
Calculate the height of the breaker mechanism so that if there is a strong impact during movement, the spring mechanism does not fail.
Install the air spring onto the strut.
Using a press washer and sealant, connect the elements.
Attach a journal bearing to the strut. It must be fixed so that the rod does not turn when turning the steering wheel of the car.
Connect the air supply tube to the airbag socket.
Press the air spring onto the shock absorber until it stops.
Make an air supply line.

Rear

The manufacturing process of the rear suspension of a KamAZ vehicle:

It is necessary to cut off the spring cup and remove all paint.
Then you need to cut the thread to the end of the rod to install the air suspension spring.
After this, you need to install a press washer, and then put a pneumatic cushion on the rod. Install the breaker mechanism.
Then press in the spring.
Install a pressure gauge with a moisture separator between the receiver and the compressor part to monitor the pressure.
Finally, install the air flow line.

The receiver can be made from a gas cylinder.

It is recommended to take a cylinder from a VAZ 2109 car, because It can withstand high pressure and also has a check valve, which speeds up the process of lifting the car body.

The diameter of the tubes from the intake valves to the receiver should not exceed 6 mm, and from the receiver to the compressor part - 8 mm.

How to make a floating suspension and other improvements to the cab of KamAZ trucks

The suspension of a truck cab is the main element responsible for the comfort and safety of the driver and the vehicle. This is especially important for cabover trucks. Each design requires an individual solution to this problem. To reduce shaking and the transmission of low-frequency vibrations from the chassis to the driver's workplace, designers are constantly improving vehicle suspension components.

However, this does not always lead to the desired results. Some owners of heavy vehicles solve these problems themselves. One of such solutions is the KamAZ floating cabin.

How to install

Air suspension installation:

Place KamAZ on the support.
Remove the plastic plugs from the trunk of the vehicle.
Unscrew the mounting nuts of the struts to gain access to the wiring gaskets.
Connect the compressor to the receiver control system unit.
Install the resulting structure on the base of the spare wheel.
Connect the wiring to the compressor and receiver, following the instructions on the wire labels.
Assemble the connected wires into a bundle and bring it out into the driver’s cabin.
Lay the harness along the cabin wall and lead it into the power unit compartment.
Connect the wires to the battery, ground and fuse block.
Remove the strut and install the prepared pneumatic strut in its place.
Remove the brake system hoses.
Disable ABS sensors.
Connect the pneumatic lines to the compressor, receiver and control unit.
Lead the air line into the engine compartment.

Installation of the pneumatic kit:

The air suspension kit is installed in addition to the standard springs and does not make changes to the standard suspension elements. Therefore, this kit does not require changes to the vehicle's title. The air spring is placed between the frame with springs on special mounting plates included in the kit. The upper mounting plate is placed on the frame in the standard holes; an additional transverse brace is placed between the fastenings to strengthen the frame and distribute the load. The lower mounting plate is placed on the bridge.

Delivery throughout the Stavropol Territory within 24 hours

In most cases, delivery on the day of order. Delivery is carried out from 10.00 to 19.00.

The day, time and place of delivery are discussed with the manager.

Payment is made in cash upon receipt of the order (upon payment you will receive sales and cash receipts).

Malfunctions and their elimination

KamAZ suspension malfunctions and repairs:

Axes offset. May be caused by a breakdown in the system, worn bushings or improper installation of the suspension mechanism. It is necessary to replace worn parts and reinstall the suspension.
Displaced tension ring. The cause of the malfunction may be the operation of the air springs in an extended state and at a low pressure level. It is recommended to replace the springs and adjust the pressure.
Breakdown in the suspension with reaction bars. It can be caused by deformation of the plate, displacement of the internal fender mechanism, or a rupture in the area of the tension ring. It is necessary to replace the plate, adjust the bump stop, eliminate the gap, and inspect the rods for defects.
Air leakage in the area of threaded inserts. The shock absorber and valve alignment should be inspected for damage. It is also necessary to adjust the mechanism hinge.

During all repair work, you should wear protective clothing: a mask or goggles.

How much does a cabin cost?

The price of the product depends on the condition, configuration, car model and many other factors. Used structures can be bought for 15-50 thousand rubles, depending on their technical condition. The price of new products can range from 250 to 300 thousand. Such cabins can be equipped with floating shock absorption systems, equipped with a berth, etc.

The most popular are structures that have undergone major repairs or restoration and have the most complete equipment. The price for such products is 75-120 thousand rubles.

Kamaz air suspension

Life hack from grandfathers who lived in the USSR: “To increase the load capacity of the car, insert tennis balls into the suspension springs.”
Cheap and cheerful and, unfortunately, not durable! If you want to improve the cargo qualities of your car, install air suspension! Air suspension for KAMAZ

The KAMAZ air suspension is an addition to the standard spring suspension.

Air suspension diagram

The air suspension on the car is built according to a four-circuit design with 8 valves, 2 valves per cushion - one valve for air supply, the second for return. The scheme will allow you to effectively control each air spring: lower the left side, raise the right side or vice versa, lower the front of the car and raise the rear, etc.

Fig.1 Moskvich-2140

Fig.2

Air suspension for KAMAZ: relying on air

In Naberezhnye Chelny, new suspension options for KAMAZ trucks and buses are being developed.

The oldest suspension of any wheeled vehicle is leaf spring. The most modern is pneumatic. It is also the most comfortable due to its progressive elasticity characteristics (this is why air suspension was introduced primarily on buses and high-class cars). And even Citroen's clever hydropneumatic suspension can be seen as a variation on the same theme, although it does not have an air compressor.

Well known and not forgotten

In the USSR, air suspension was first used on LiAZ-677 city buses in the late 1960s. And the first domestic serial truck with air suspension was the rather rare KAMAZ-5460 truck tractor, which was put on the assembly line in 2010. To some extent, it can be considered a carrier of units for the promising KAMAZ-5490 truck.

It is well known that a truck tractor needs air suspension on the drive axle to duck under a semi-trailer when coupling and uncoupling, as well as to improve the smoothness of the ride. The curb weight of the car is reduced by 200–300 kg, the suspension can more easily withstand small overloads, and a damaged air spring can be replaced even on the side of the road.

But trucks with front air suspension are rare in Russia. Meanwhile, there is a modification of the KAMAZ-65117 6×4 vehicle, in which all three axles are on air. The vehicle was developed for the Kamateiner project - this is a long-wheelbase chassis on which various quick-detachable superstructures are installed. Such a scheme was supposed to ensure an increase in the profitability of transportation by two to three times, but it did not arouse interest among carriers and therefore stalled.

The achievements of Chelny, which designed this air suspension, are very interesting. For example, balanced air suspension of drive axles for 6x4 trucks has good potential, taking into account axle load limitations. Based on such a balancer, it is easy to create a version of a 6x2 long-haul truck, including one with front air suspension.

Reliable, comfortable all-round air suspension is also useful for a 4x2 truck tractor. Such innovations will suit the KAMAZ-5490 family of trucks - those with the Mercedes-Benz Axor cab. The Rostar suspension may be interesting for creating 6x6 all-wheel drive three-axle shifters, which are known for their exhausting shaking on the off-road. Moreover, springs can also be left for the front drive axle.

Complete independence

Now specialists and engineers of the KAMAZ scientific and technical center are working on creating an independent front suspension for trucks and buses. Two options are being developed. Firstly, it is a pivot suspension on double wishbones, with an air spring located on a bracket at the top of the steering knuckle. They are starting to install this on NefAZ‑52974 and KAvZ‑5297 buses. There are two versions that differ in axle load: a fairly universal suspension - 5.5 tons, and also very promising for tourist buses and as a suspension component for long-haul trucks - 8.2 tons.

In 2022, it is planned to supply about one and a half hundred front axles with independent air suspension to the Neftekamsk and Kurgan plants.

The second type of split axles with pneumatics is in the process of finalizing the design. This axle is also made using a double wishbone design, but ball joints are used here (pins are used in ZF bus independent suspensions and Volvo FH truck suspensions). The new suspension does not copy existing ones: it is developing its own, original design, taking into account Russian operating conditions. And, as experience shows, we always do better.

Installation of air suspension on Kamaz

Part 1. Kamaz on air cushions

KamAZ 55111 air suspension

Air suspension mounting. Install air suspension. Assembling the lower mount

Kamaz pneumatic 2 regulator operation

the whole truth about air bags on Kamaz

Install the upper air suspension mounts

Removing the Kamaz 55111 gearbox with air springs without touching the divider.

Kamaz floating cabin from Murad. Rework.

If you compare the softness of the ride from 0 to 10, before the modification it was 1, but now it’s 10+

The whole alteration came out cheaper than the cost of one pack of springs for this car.

This modification was put to the test on September 19, 2018, and we will test the survivability of this idea.

In the future I plan to install the same pillows on Mazda Titan gp. 3 t.

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Description
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Applicability 12
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Replacing a KAMAZ air spring

It is not possible to fix the problem yourself with the means at hand, so when diagnosing a defect in the air spring, you must contact the specialists of the service center.
Before carrying out repair work, you need to select the latest components. The service station masters will do this for you. When purchasing yourself, you should pay attention to the diameter of the product in order to calculate the load capacity and operating pressure of the element. Experts recommend not to forget that the load is distributed over four wheels. When KAMAZ trucks are fully loaded, the rear axle is subjected to more pressure than the front axle. If there is a spring, the load is distributed across both parts. The stroke length is also a measurement necessary for the selection of components. This is the difference between the pillow being compressed and extended.

Air springs are installed in the rear springs. The specialist installs a small corner on the spar to use it as a support. The lower plate mount is located between the spacers and springs of the KAMAZ. They are installed on the front axle, while the lower mount is fixed to the corresponding lever. The upper one, in turn, is attached to the cross beam.

Source

Description - air suspension 4308

The front auxiliary air suspension kit for KAMAZ, Kamazenok (KAMAZ 4308) is installed in addition to the standard spring suspension of the vehicle and allows you to reduce the load on the springs, increase the comfort of the vehicle and improve the cargo characteristics of the vehicle. Installing an air suspension will allow the KAMAZ 4308 to carry more cargo without loss of controllability, eliminate spring sagging and breakage, and reduce body sway and roll. Air suspension for KAMAZ, Kamazenok (KAMAZ 4308) is an excellent solution for increasing the service life of the standard spring suspension.

Installation of auxiliary air suspension does not require special skills and takes an average of 4 hours. It is possible to install an auxiliary air suspension kit for KAMAZ, Kamazenok (KAMAZ 4308) in our workshop, in any car service center, or with your own hands.

Air suspension KAMAZ, Kamazenok (KAMAZ 4308), front axle, Ar /> 810 1080 Air suspension KAMAZ, Kamazenok (KAMAZ 4308), front axle, Aride Buy air suspension on the front axle, KAMAZ brand vehicles, model KAMAZ 4308, Aride in St. Petersburg - competitive prices, guarantee and delivery to any city in the Russian Federation

Features of air springs for KAMAZ 4308:

Reduced wear on springs and shock absorbers (standard springs on your car will last longer, because air suspension will reduce the load on them, as well as on other suspension elements)
Elimination of noise and vibration of the suspension and impacts of the bump stop when overloaded (the air suspension completely eliminates the situation when a commercial vehicle rests on the bump stops)
The ability to install air suspension on tired springs (after installing the air suspension, springs requiring replacement will last for a long time)
Correct position of the body under any load (always a horizontal position of the body of a commercial vehicle, regardless of the load, and this means the correct operation of the head light and a reduction in braking distance)
Reducing roll and sway of the car (the air suspension prevents the car from rolling over an overloaded side and is always in a horizontal position)
Increased comfort for the driver and passengers (a significant increase in comfort when driving cars on bad and uneven roads, both for the driver and passengers (on passenger minibuses)
Increased profits from transportation (air suspension - air spring - this is the ability to transport 1.5 times more cargo in 1 flight + savings on replacing springs and traffic police fines for overloading
Ability to control vehicle overhang when loading and unloading (adjusting rear clearance to level the floor of a commercial vehicle booth with the level of the ramp floor for convenient loading)
Long service life of the air suspension (the air suspension does not require any additional maintenance, and works effectively for 5 - 6 years under any operating conditions, be it frost, dirt, salts and reagents. Operating pressure up to 15 atmospheres)
Increased ride comfort and softness possible
The “Goat” effect is eliminated

Contents of delivery

The air suspension kit is designed specifically for the car and includes two pneumatic elements, brackets for mounting to the frame and axle, fasteners, fittings for inflation from an external compressor, and instructions for do-it-yourself installation.

The kit includes:

American bellows-type pneumatic elements (air springs), which are optimally sized for a given vehicle. They do not require any maintenance due to the reliable rubber-cord construction and last for more than 400 thousand vehicle mileage in any road conditions.
fastening elements of our own factory production from 6mm Russian steel, developed specifically for this car. These brackets are reliable, easy to install and will last a long time. The brackets are powder coated, which protects them from rust throughout their entire service life.
a set of Russian bolts, washers, nuts for assembling the kit
air fittings and pneumatic line from Camozzi, the kit includes 7 meters of pneumatic hose, which allows you to install the inflation nipple in any part of the car
nipple for deflation and inflation with any external AirLift compressor
installation instructions
All equipment has been tested under various conditions, which gives us confidence in the reliability of this air suspension kit. The kit comes fully disassembled with step-by-step installation instructions. Unlike our competitors, we do not hide what the kits are made of and allow the client to independently familiarize themselves with all the fasteners during installation to ensure their reliability and ease of installation.