Suspension maintenance manual

Jiefang
CA4250P25K2T2E5A80
Flat diesel semi trailer
Maintenance manual
Suspension

FAW Jiefang Qingdao Automobile Co., Ltd

 Suspension maintenance manual
September 2020

Catalogue
1.Front suspension................................................................................................................................................................1

1.1Specifications..............................................................................................................................................................1

1.1.1 Spring assembly..............................................................................................................................................1

1.1.2 Shock absorber...............................................................................................................................................1

1.2 Structure.....................................................................................................................................................................1

1.3 Operation before and after disassembly.....................................................................................................................3

1.4 Removal and installation of front suspension............................................................................................................4

1.4.1 Decomposition sequence................................................................................................................................4

1.4.2 Assembly sequence........................................................................................................................................5

1.4.3 Maintenance standard.....................................................................................................................................5

1.4.4 Tightening torque...........................................................................................................................................6

1.4.5 Lubricant.........................................................................................................................................................6

1.4.6 Specialtools.....................................................................................................................................................7

1.4.7 Maintenance method......................................................................................................................................7

1.5 Remove and install the leaf spring assembly.............................................................................................................8

1.5.1 Disassembly sequence....................................................................................................................................8

1.5.2 Assembly sequence........................................................................................................................................8

1.5.3 Tightening torque...........................................................................................................................................8

1.5.4 Maintenance method......................................................................................................................................8

1.5.5 Common faults...............................................................................................................................................9

2. Rear suspension..............................................................................................................................................................10

2.1 Specifications...........................................................................................................................................................10

2.1.1 Air spring assembly......................................................................................................................................10

2.1.2 Shock absorber assembly.............................................................................................................................10

2.2. Structure..................................................................................................................................................................11

2.3 Working principle....................................................................................................................................................11

2.4 Check and adjust on board.......................................................................................................................................12

2.4.1 Maintenance standard...................................................................................................................................12

2.5 Air spring bracket mounting hole spacing...............................................................................................................12

2.5.1 Maintenance standard...................................................................................................................................12

2.5.2 Tightening torque.........................................................................................................................................12

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2.6 Operation before disassembly and after installation of rear suspension..................................................................13

2.6.1 Operation before disassembly......................................................................................................................13

2.6.2 Operation after installation...........................................................................................................................13

2.7 Removal and installation of rear suspension...........................................................................................................14

2.7.1 Tightening torque.........................................................................................................................................16

2.8 Common faults of rear air suspension.....................................................................................................................18

 Suspension maintenance manual
1.Front suspension

1.1Specifications

1.1.1 Spring assembly

Length x width x
Name Type thickness - number of Number of leaves
tablets

Front leaf spring

assembly Little leaf spring 1754×90×28-2(mm) 2

1.1.2 Shock absorber

Units:mm

Minimum Maximum outer

Work Maximum Connection
Type Stroke compression diameter of dust
bore tensile length form
length cover

Double acting Upper pin

φ36 285 720±3 435±3 φ66
cylinder lower pin

1.2. Structure

Leaf spring assembly 4 and shock absorber 3 are mounted between frame 1 and front axle 2 to support the
body weight, absorb vibration and impact from the road, prevent vibration and impact from being directly
transmitted to the body, thus protecting the body, people and goods on the vehicle. This kind of structure can
also restrain the irregular vibration of the wheel and ensure the balance of driving.

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 Suspension maintenance manual

Number Part name Number Part name

1 Frame 4 Leaf spring assembly

2 Front axle 5 Stabilizer bar

3 Shock absorber

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1.3 Operation before and after disassembly

Work before disassembly

Place wheel block 1.

Jack up the center of the front axle with jack 2.

Support the front frame on a sturdy tripod 3.

Warning

★The wheel chock should be secured to prevent the vehicle from moving.

★Do not remove the wheel block until all the work is completed.

★It is extremely dangerous to hold a car with only a jack. Always use a sturdy tripod to support the frame.

★The jack and tripod shall be placed in the correct position before all work is completed and shall not be taken
away during work.

Operation after installation

In the reverse order of disassembly.

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1.4 Removal and installation of front suspension

1.4.1 Decomposition sequence

Number Part name Number Part name

1 Nuts - for fastening u-bolts 27 Grease nozzle

2 U-bolt- front leaf spring 28 Pin - front leaf spring bracket

3 U-bolt- front leaf spring 29 Hexagonal nut

4 Cover-front leaf spring 30 Spring washer

5 Cushion-front leaf spring 31 Hexagonal head bolt

6 Hexagonal nut 32 Grease nozzle

7 Spring washer 33 Pin - front brackets of front leaf spring

8 Large washer 34 Front leaf spring assembly

9 Hexagonal head neck bolt 35 Left (right) lower bracket assembly -

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front shock absorber

10 Hexagonal head neck bolt 36 Ring-front leaf spring

11 Shock absorber assembly 37 Hexagon head flange bolt

12 Hexagonal head bolt 38 Hexagon flange nuts

13 Spring washer 39 Hexagon head flange bolt

Cover - front transverse stabilizer bar Left front bracket - front leaf spring
14 40
bracket

15 Support - front transverse stabilizer bar 41 Right front bracket - front leaf spring

16 Bushing - front transverse stabilizer bar 42 Hexagon flange nuts

17 Hexagonal nut 43 Hexagon head flange bolt

Spring washer Bracket-front transverse stabilizer bar

18 44
lazy arm

19 Hexagonal head bolt 45 Hexagon flange nuts

20 Front transverse stabilizer bar assembly 46 Hexagon head flange bolt

21 Hexagon head flange bolt 47 Front shock absorber upper bracket

Inner washer - release bolt for Hexagon flange nuts

22 48
transverse stabilizer bar lazy arm

Lazy arm and bush assembly - front Hexagon head flange bolt
23 49
transverse stabilizer bar

Hexagonal nut Rear bracket assembly - front leaf

24 50
spring

25 Spring washer 51 Hexagon head flange bolt

26 Hexagonal head bolt  Non-reusable parts

Remarks

★To remove the ring pin 28 and 33, use a copper rod to knock them off.

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 Suspension maintenance manual
★Unless front bracket 40, 41 and back bracket 50, transverse stabilizer arm bracket 44 and upper bracket 47 of
shock absorber are damaged, do not remove them.

1.4.2Assembly sequence

In the reverse order of disassembly.

1.4.3 Maintenance standard

Units: mm

Correction
Part Maintenance items Standard values
methods

Clearance between leaf spring pin and spring 0.065～0.447 Replace

28、33、34、50
bushing and bracket bushing

28、33、36、40 Clearance between leaf spring pin and leaf spring

0～0.104 Replace
、41 bracket and lifting ring

1.4.4 Tightening torque

Unit：N•m

Tightening
Part Tightened part Remarks
torque

Gear oil for bolt

1 Nuts - for fastening u-bolts 500±50
threads

Gear oil for bolt

6 Hexagon nut (for fastening shock absorbers) 260±50
threads

Hexagon head bolt (for tightening front transverse Gear oil for bolt
12 200±40
stabilizer bar bracket cover ) threads

Hexagon nut (for tightening front transverse Gear oil for bolt
17 400±80
stabilizer bar) threads

Hexagon flange bolt (for fastening front transverse Gear oil for bolt
21 430±80
stabilizer lazy arm ) threads

Hexagon nut (fastening spring support pin and ring Gear oil for bolt
24、29 100±20
pin) threads

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Hexagon flange nut (for fastening spring front
38 290±60
bracket)

Hexagon flange nut (for fastening transverse

42 220±40
stabilizer bar lazy arm bracket)

Hexagon flange nut (for fastening shock absorber

45 200±40
upper bracket)

Hexagon flange nut (for fastening steel leaf spring

48 400±80
back bracket)

Note：even tightening.

1.4.5 Lubricant

Part Coating position Prescribed lubricant Remarks

According to the
1 Bolts corresponding to nuts Gear oil [Grade 80W/90 GL-5]
visual needs

According to the
27、32 Grease nipple All-weather gm lithium grease
visual needs

According to the
28、33 Pin All-weather gm lithium grease
visual needs

1.4.6 Specialtools

Part Tool name and shape Part number Use

"30" Socket head

Remove and install u-

1 3916104-56A bolts and nuts from front
leaf springs

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1.4.7 Maintenance method

Removal and installation of U-bolt and nut [1]

: a socket wrench is used for the U-bolt and nut of

the front leaf spring;

“30” Socket head

A: Install.

B: Remove.

During installation, apply gear oil to bolt threads,

pretighten with pneumatic wrench, and then re-

Pneumatic wrench tighten with manual wrench, and the torque is
(500±50) N·m.

Manual wrench

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 Suspension maintenance manual
1.5 Remove and install the leaf spring assembly

1.5.1 Disassembly sequence

Number Part name Number Part name

1 Bushing - rear leaf spring 3 Center bolt - rear leaf spring

2 Hexagonal nut 4 Leaf spring

1.5.2Assembly sequence

In the reverse order of disassembly.

1.5.3 Tightening torque

Units: N•m

Part Tightened part Tightening torque Remarks

2 Hexagonal nut 110±10 Gear oil for bolt threads

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 Suspension maintenance manual
1.5.4 Maintenance method
1.5.5 Common faults
Fault phenomenon
When the vehicle is running, the
chassis has abnormal sound
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Removal and installation of hexagon nuts [2].
[Remove]
Make mating mark A on the side of leaf spring [4].
Press the leaf spring [4] with the press, remove the
center nut [2].
[Installation]
Before assembly, align the matching mark A on the
side of leaf spring [4].
Pressure with a pressHold leaf spring 4 and tighten
center nut 2.
Tightening torque: (110±10) N·m
Reason analysis Elimination method
Leaf spring fracture Replace leaf spring
Disc spring ear bushing worn or Replace bushing or grease
lacking grease
Check pin bolts for loose or
The ring pin moves in the axial damaged .
direction
Replace the bushing
 Suspension maintenance manual
Shock absorber rubber bushing
wear
Tighten again according to the
Shock absorber mounting loose specified torque

Broken spring support or worn Replace the bracket

crotch
Replace the shock absorber
Shock absorber dust cover askew,
scratch work cylinder Replace transverse stabilizer bar or
bushing
Transverse stabilizer bar fracture or
bushing wear

The plate spring is broken at the Replace the plate spring and
center hole, and the u-bolt side is The U-bolt is loose tighten the u-bolt according to the
worn specified torque

When a vehicle is subjected to

heavy impact, there is metal impact Non-metallic cushion is damaged Replace cushions
sound.

Leaf springs are permanently

The car leans heavily to one side Replace the plate spring
deformed or broken

Continuous abnormal vibration

occurs when driving, and the The shock absorber obviously
external cylinder of shock absorber leaks and reduces the damping Replace the shock absorber
is not hot when driving for about force
10km on bad roads

2. Rear suspension

2.1 Specifications

2.1.1 Air spring assembly

Unit: mm

Name Type Working Maximum Minimum The largest

height tensile length compression diameter
length

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 Suspension maintenance manual
Axle front air spring Diaphragm 283 468 198 300
assembly type

Drive axle rear air spring Diaphragm 283 468 198 280
assembly type

2.1.2 Shock absorber assembly

Unit: mm

Type Work Stroke Maximum Minimum Maximum outer Connectio

bore tensile length compression diameter of dust n form
length cover

Double acting φ45 250 675±3 425±3 φ75 Upper pin

cylinder lower pin

2.2. Structure

Number Part name Number Part name

1 Frame 6 Upper reaction rod assembly

2 Intermediate axle assembly 7 Lower reaction rod assembly

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3 Rear axle assembly 8 Air suspension large bracket

4 Air spring bracket 9 Stabilizer bar

5 Air spring assembly 10 Shock absorber assembly

2.3 Working principle

Air spring assembly 5 and shock absorber assembly 10 are installed between the air spring arm 4 of frame 1,
middle axle assembly 2 and rear axle assembly 3 to support the weight of the body, absorb the vibration and
impact from the road, prevent the vibration and impact directly to the body, thus protecting the body, the people
on the car and the goods. This structure can also restrain the irregular vibration of the wheel and ensure the
smooth running. The upper reaction lever assembly 6 and the lower reaction lever assembly 7 are mounted
between middle axle assembly 2 and rear axle assembly 3 and frame 1 and large bracket 8 of air suspension,
bearing transverse and longitudinal forces. Install lateral stabilizer bar 9 on the front end of middle axle assembly
2 and back end of rear axle assembly 3, which is used to improve the suspension side inclination stiffness and
reduce the body side inclination. In addition, the v-shaped reaction bar assembly 6 is used for the upper reaction
bar to inhibit roll.

2.4 Check and adjust on board

2.4.1 Maintenance standard

Unit: mm

Maintenance items Standard values Correction methods

Distance difference between left and right Less than 5 Adjustment

intermediate axle and rear axle

2.4.2 Tightening torque

Unit：N•m

Tightened part Tightening torque Remarks

Lower reaction rod bolt 600±100 -

2.5 Air spring bracket mounting hole spacing

2.5.1 Maintenance standard

Maintenance items Code name Standard values(Inside [] is the Correction

basic size) methods

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 Suspension maintenance manual
Middle bridge air spring bracket arm L1 [780]777.5~782.5 Adjustment
front side mounting hole distance

Middle bridge air spring bracket arm L2 [780]777.5~782.5 Adjustment

rear side mounting hole distance

Rear axle air spring bracket arm front L3 [780]777.5~782.5 Adjustment

side mounting hole distance

Rear air spring bracket arm front side L4 [780]777.5~782.5 Adjustment

mounting hole distance

2.5.2 Tightening torque

Tightened part Tightening torque Remarks

A nut for a u-bolt 700±50 -

2.6 Operation before disassembly and after installation of rear suspension

2.6.1 Operation before disassembly

Place wheel block 1.

Jack up the rear axle with the jack 2.

Support the rear frame on a solid tripod 3.

Warning

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 Suspension maintenance manual
★The wheel chock should be secured to prevent the vehicle from moving.

★Do not remove the wheel block until all the work is completed.

★It is extremely dangerous to hold a car with only a jack. Always use a sturdy tripod to support the frame.

★The jack and tripod shall be placed in the correct position before all work is completed and shall not be taken
away during work.

2.6.2 Operation after installation

In the reverse order of disassembly.

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 Suspension maintenance manual
2.7 Removal and installation of rear suspension

Number Part name Number Part name

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 Suspension maintenance manual

Hexagon flange bolt thick rod (standard Rear lower reaction rod with rubber
1 39
type) joint assembly

2 Transverse stabilizer bar bracket with 40 Axle front air spring assembly
bushing assembly

3 Upper cover plate assembly - air 41 Large bracket - air suspension

suspension

Hexagon flange bolt thick rod (standard Hexagonal head bolt

4 42
type) SPL Hexagon small flange locknut

5 Hexagon head flange bolt 43 Axle front air spring assembly

Reaction rod of front balance Front lower reacting rod with rubber
6 44
suspension joint assy

Rubber joint assembly for front top Left arm with locating pin assembly -
7 45
reaction rod air spring

Hexagonal head bolt

8 Upper bracket - rear shock absorber 46
SPL Hexagon small flange locknut

9 Rear shock absorber assembly 47 Nuts - for fastening u-bolts

Hexagon flange bolt thick rod (standard Hexagon flange bolt thick rod (standard
10 48
type) type)

11 SPL Hexagon small flange locknut 49 Bushing - transverse stabilizer bar

12 Hexagon flange bolt thick rod (standard 50 Cover - stabilizer bar

type)

13 Upper cover plate assembly - air 51 Rear transverse stabilizer bar assembly
suspension

Hexagon flange bolt thick rod

14 (standard) 52 Drive axle rear air spring assembly

SPL Hexagon small flange locknut

15 Upper cover plate assembly - air 53 Stabilizer arm assembly

suspension

Hexagon flange bolt thick rod

16 (standard) 54 Nut, spring washer

SPL Hexagon small flange locknut

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 Suspension maintenance manual

Hexagonal head bolt

17 55 U-bolt - rear air suspension
SPL Hexagon small flange locknut

Leaf spring fifth piece and clamp

18 Upper bracket - rear shock absorber 56
assembly

19 Rear shock absorber assembly 57 Bracket-rear leaf spring

20 Hexagon flange bolt thick rod (standard 58 Adaptor seat-air spring

type)

21 Rubber joint assembly for rear upper 59 Large washer

reaction rod

Hexagon flange bolt thick rod

22 Rear upper reaction bar 60
(standard)

23 Hexagon head flange bolt 61 Height sensor assembly

24 Hexagon flange bolt thick rod (standard 62 Assembling bolt

type)

25 Upper cover plate assembly - air 63 Axle front air spring assembly
suspension

26 Hexagon flange bolt thick rod (standard 64 Adaptor seat-air spring

type)

27 U-bolt - rear air suspension 65 Double-end stud

28 Rear leaf spring fifth piece and clamp 66 Spring washer

assembly

Hexagon flange bolt thick rod (standard

29 Bracket-rear leaf spring 67
type)

30 Stabilizer arm assembly 68 Support bracket - Lift airbag

31 Drive axle rear air spring assembly 69 SPL Hexagon small flange locknut

32 Rear transverse stabilizer bar assembly 70 Stents

Upper cover plate assembly - air

33 Cover - stabilizer bar 71
suspension

34 Bushing - transverse stabilizer bar 72 Nut, spring washer

Hexagon flange bolt thick rod (standard Hexagon flange bolt thick rod (standard
35 73
type) type)

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 Suspension maintenance manual
36 Hexagonal head bolt 74 Big support

37 Right arm with locating pin assembly - 75 SPL Hexagon small flange locknut
air spring

38 Double-end stud

2.7.1 Tightening torque

Unit：N•m

Tightened part Tightening torque

Bolt (for fastening air springs) 240±40

Nut-for fastening U-bolt 700±50

Nut (for fastening air springs) 35±5

Hexagon flange bolt (for fastening the lower cover of stabilizer bar) 430±80

Hexagon flange nut (for fastening stabilizer lazy arm) 290±60

Hexagon flange nut (for fastening stabilizer lazy arm) 290±60

Hexagon flange nut (for fastening shock absorbers) 600±100

Hexagon flange nut (for fastening shock absorbers) 600±100

SPL hexagon small flange face locking nut (for fastening reaction rod) 600±100

SPL hexagon small flange face locking nut (for fastening reaction rod) 600±100

Hexagon flange bolt (for fastening small end of reaction bar) 550±80

SPLhexagon small flange face lock nut(fastening on the reaction bar 900±100
large end)

Hexagon flange nut (for fastening support on stabilizer bar) 200±40

Hexagon flange nut (for fastening air spring upper cover plate) 200±40

Hexagon flange nut (for fastening shock absorber upper bracket) 200±40

Remarks: warm tips, the key parts must be tightened in accordance with the torque.

Other considerations for using the air spring assembly:

Avoid damaging the surface of metal connectors of air spring assembly during assembly to prevent premature

failure of air spring system caused by corrosion；

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 Suspension maintenance manual
The air spring assembly shall not be in a state of transition tension in order to prevent the air bag from

detaching from the upper and lower connecting parts and the air spring system from failing；

Avoid working in high temperature environment as far as possible, so that the fatigue crack caused by the

aging of air-defense spring material will aggravate the failure of air spring system；

When disassembling and repairing the airbag and its surrounding parts, avoid splashing oil on the airbag to

prevent its corrosion and shorten its service life；

In the process of using air spring assembly, it is necessary to avoid all kinds of solvents, grease, etc. on the air

bag, so as to prevent the premature failure of air spring system caused by the continuous wetting corrosion of
outer rubber；

Avoid overloading. Because when the vehicle is overloaded, the height sensor will maintain the set height, that

is, increase the internal pressure of the air spring, so that the piston will be damaged, ring hoop and piston joint,
the air bag may appear circumferential incision, causing premature failure of the air spring system;

If the air spring begins to wear due to the influence of external force on the outer rubber, on the one hand, it is
necessary to replace the air spring quickly, on the other hand, it is necessary to eliminate the causes of these wear in a
timely and lasting manner. If the long-term delay does not replace, as a result of the car overload and cause excessive
load, will lead to the air spring overload rupture.

2.8 Common faults of rear air suspension

1. The air spring has less air intake on one side (phenomenon)

(1) Check whether the air passage with less intake is leaking.

Operation: use soapy water, apply appropriate amount to each joint,

and then observe whether there are bubbles. If there are bubbles,
there is a leak in the air path.

(2) There is a "dead knot" in the pipeline.

Operation: straighten out the pipeline on the side with less air
intake.

2. Vibration absorber leaks liquid

Possible reasons:

(1) The type of shock absorber is incorrect;

(2) The suspension height is not right: too high;

(3) Insufficient clearance around the shock absorber;

(4) Installation of shock absorber is incorrect, such as inversion,

installation position of bracket on shock absorber is incorrect.

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 Suspension maintenance manual
Processing: replacement.

Explanation: the shock absorber will produce high temperature in

high strength work, which will vaporize and vaporize a small
amount of oil molecules in hydraulic oil and penetrate outside the
oil chamber, forming an ash-like attachment on the external surface
of the shock absorber. this phenomenon is normal and should not be
replaced at will.

3. The shock absorber mounting ring is elongated and opened, or the

shock absorber is opened.

Possible reasons:

(1) Suspension height: too high;

(2) Installation of shock absorber is incorrect: for example, the

mounting position of bracket on shock absorber is too high;

(3) The type of shock absorber is incorrect.

Processing: replacement.

4. Damage of shock absorber bushing

Possible reasons:

(1) The working height is too high, that is, the driving condition of
the vehicle is not right;

(2) Installation of shock absorber is incorrect, installation bolt is not

tightened or loosened;

(3) The type of shock absorber is incorrect;

(4) Normal wear.

Processing: replacement.

5. Air spring wear: side wear and even wear holes

Possible reasons:

The upper and lower reaction bar of the bridge is damaged, the
middle bridge or the rear bridge is displaced, and the air spring and
tire friction occur;

(2)The support of the upper and lower reaction bar of the bridge and
the support of the frame beam are damaged, the middle bridge or the

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rear bridge shift, and the air spring and tire friction occur;

(3)Large supports of air suspension are damaged, middle or rear

Bridges are displaced, and air springs are rubbed against tires.

(4)Shock absorber damage caused by interference with air spring

friction.

Processing method: If the curtain layer is exposed, replace it.

6. There are bubbles on the air spring

Possible reasons:

(1) Small cracks appeared in the inner rubber and caused bubbles in
the outer rubber. As long as the air spring does not leak, it can still
be used.

(2) Residual air in air spring.

Treatment: As long as the air spring is not leaking, it can still be

used.

7. Air spring burst

Possible reasons:

(1)Overload is serious, air spring internal buffer block damage, fall

into the air spring, friction inner layer of rubber, finally lead to cloth
layer exposed to the inside, air spring is layered, further cause air
spring outer bubble, and then burst.

(2)Due to the aging of rubber and cloth layer, air spring is a

vulnerable part, therefore, the failure of air spring after long-term use
is normal.

Treatment: replacement.

8.Cracked upper edge plate of air spring

Possible reasons:

(1)Air spring cover plate and piston eccentric, the air spring force is
uneven, resulting in cracks.

Treatment: replacement.

9.Air spring fold

Possible reasons:

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(1)The upper and lower connections are twisted when air springs are
installed.

Treatment: Loosen the lower piston connecting bolt and readjust it.

10.The air spring is worn through the piston area with flaps and even
holes

Possible reasons:

(1) The piston of air spring base is stuck with sharp objects such as
sand and gravel.

Treatment: replacement.

10.The air spring is worn through the piston area with flaps and even
holes

Possible reasons:

(1) The piston of air spring base is stuck with sharp objects such as
sand and gravel.

Treatment: replacement.

11. Cracking of air spring

Possible reasons:

(1) The air spring is covered with grease and so on, which causes
premature aging.

(2) Normal aging.

Processing: replacement.

12. Air spring skew

Possible reasons:

(1)The position of the parts connected with the air spring is

incorrect, and the air spring is slanted longitudinally.

Processing method: Adjust the position of adjacent parts, if it can not

be adjusted to continue to use, the life of air spring will be
shortened.

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