Suspension maintenance manual

Jiefang
CA4250P25K2T1E5A80
Flat diesel semi trailer
Maintenance manual
Suspension

FAW Jiefang Qingdao Automobile Co., Ltd

November 2020
 Suspension maintenance manual

Contents
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 Work before disassembly and after installation..............................................................................................................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 Special tools.................................................................................................................................................................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
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.......................................................................................................................................................17
2.8 Common faults of rear air suspension..........................................................................................................................19
 Suspension maintenance manual
1.Front suspension
1.1Specifications
1.1.1 Spring assembly

Lengthx width x
The main piece of
Name Type thickness - number of
number
tablets

Front leaf spring

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

1.1.2 Shock absorber

Unit：mm
Minimum Maximum outer
Working Maximum Connection
Type Journey compression diameter of dust
bore stretch length form
length cover

Two-way acting Upper pin

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

1.2 Structure
The leaf spring assembly 4 and the shock absorber 3 are installed between the frame 1 and the front axle 2
to support the weight of the vehicle body, absorb the vibration and impact from the road surface, and prevent the
vibration and impact from being directly transmitted to the vehicle body, thus protecting the vehicle body, people
and goods on the vehicle. This structure can also restrain the irregular vibration of wheels and ensure the running
balance.

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Serial
S/N Part Name Part Name
number

1 Frame 4 Leaf spring assembly

2 Front Axle 5 Lateral stabilizer bar

3 Absorber

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1.3 .Work before disassembly and after installation

Work before disassembly

Place wheel block 1.
Jack up the center of the front axle with jack 2.
Support the front frame on a solid tripod 3.
Warning
★The wheel block should be fastened to prevent the car 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.

Work after installation

In the reverse order of disassembly.

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 Suspension maintenance manual
1.4 Removal and installation of front suspension

1.4.1 Decomposition sequence

Serial Serial
Part Name Part Name
number number

1 Nuts - for fastening u-bolts 27 Curved neck grease nipple

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

3 U-bolt - front leaf spring 29 Hexagon nut

4 Cover plate-front leaf spring 30 Spring washer

5 Cushion-front leaf spring 31 Hex socket head bolt

6 Hexagon nut 32 Curved neck grease nipple

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

8 Large washer 34 Front leaf spring assembly

Left (right) lower bracket assembly -

9 Hexagonal head neck bolt 35
front shock absorber

10 Hexagonal head neck bolt 36 Lifting ring-front leaf spring

11 Shock absorber assembly 37 Hexagon head flange bolt

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12 Hex socket head bolt 38 Hexagon flange nuts

13 Spring washer 39 Hexagon head flange bolt

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

15 Bracket-front stabilizer bar 41 Right front bracket - front leaf spring

16 Bushing-front stabilizer bar 42 Hexagon flange nuts

17 Hexagon nut 43 Hexagon head flange bolt

18 Spring washer 44 Bracket-front stabilizer bar boom

19 Hex socket head bolt 45 Hexagon flange nuts

20 Front stabilizer bar assembly 46 Hexagon head flange bolt

21 Hexagon head flange bolt 47 Upper bracket of front shock absorber

Inner washer - release bolt for transverse

22 48 Hexagon flange nuts
stabilizer bar lazy arm

Boom and bushing assembly-front

23 49 Hexagon head flange bolt
stabilizer bar

24 Hexagon nut 50 Rear bracket assembly-front leaf spring

25 Spring washer 51 Hexagon head flange bolt

26 Hex socket head bolt  Non-reusable parts

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

1.4.2 Assembly sequence

In the reverse order of disassembly.

1.4.3 Maintenance standard

Units: mm
Standard Correction
Part Maintenance projects
values methods

Clearance between leaf spring pin and spring 0.065～0.447 Replace

28, 33, 34, 50
bushing and bracket bushing

Clearance between leaf spring pin and leaf spring

28, 33, 36, 40, 41 0～0.104 Replace
bracket and lifting ring

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 Suspension maintenance manual
1.4.4 Tightening torque

Unit：N•m
Tightening
Part Screwed parts Remarks
torque

Apply gear oil to

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

Apply gear oil to

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

Hexagon head bolt (for fastening the front stabilizer Apply gear oil to
12 200±40
bar bracket cover) bolt threads

Hexagon nut (for tightening front transverse Apply gear oil to

17 400±80
stabilizer bar) bolt threads

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

Hexagon nut (fastening spring support pin and ring Apply gear oil to
24、29 100±20
pin) bolt threads

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：Uniform tightening.

1.4.5 Lubricant

Part Coating position Prescribed lubricant Number

The bolt corresponding to the

1 Gear oil [brand 80W/90 GL-5] Visual needs
nut

Grease nipple (bent neck Lithium - based lubricating grease

27、32 Visual needs
type) for all - weather vehicles

Lithium - based lubricating grease

28、33 pin Visual needs
for all - weather vehicles

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 Suspension maintenance manual
1.4.6 Special tools

Part Tool name and shape Part number Use

"30" Socket head

Removal and installation

1 3916104-56A of U-bolt and nut of
front leaf spring

1.4.7 Maintenance method

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

：Socket wrench for U-bolt and nut of front leaf
spring；
"30" Socket head
A: install.
B：Disassemble.
During installation, apply gear oil to bolt threads,
pretighten with pneumatic wrench, and then re-
tighten with manual wrench, and the torque is
(500±50) N·m.
Pneumatic wrench

Manual wrench

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 Suspension maintenance manual
1.5 Remove and install the leaf spring assembly

1.5.1 Disassembly sequence

Serial Serial
Part Name Part Name
number number

1 Bushing-Rear Leaf Spring 3 Center bolt - rear leaf spring

2 Hexagon nut 4 Leaf spring

1.5.2 Assembly sequence

In the reverse order of disassembly

1.5.3 Tightening torque

Unit: N•m
Part Screwed parts Tightening torque Remarks

Apply gear oil to bolt

2 Hexagon nut 110±10
threads

1.5.4 Maintenance method

Hexagon nut[2]disassembly and installation

[Disassembly]
Make mating mark A on the side of leaf spring [4].

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 Suspension maintenance manual
1.5.5 Common faults
Fault phenomenon
When the vehicle is running, the
chassis has abnormal noise
The plate spring is broken at the
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
Causes of complaints Elimination method
Leaf spring fracture
Wear or lack of grease in leaf Replace leaf spring
spring ear bushing
Replace bushing or add grease
The eye pin moves in the axial
Check whether the pin bolts are
direction
loose or damaged
Shock absorber rubber bushing
Replace the bushing
wear
Tighten again according to the
Shock absorber mounting loose
specified torque
Broken spring support or worn
Replace the bracket
crotch
Replace shock absorber
Shock absorber dust cover askew,
scratch work cylinder Replace transverse stabilizer bar or
bushing
Transverse stabilizer bar fracture or
bushing wear
Loose U-bolt Replace the plate spring and
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 Suspension maintenance manual
center hole, and the u-bolt side is 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 outer The damping force is reduced due
cylinder of shock absorber is not to obvious oil leakage of shock Replace shock absorber
hot by touching when driving on a absorber
bad road for about 10km

2. Rear suspension
2.1. Specifications
2.1.1 Air spring assembly

Unit: mm
Minimum
Working Maximum The largest
Title Type compression
height stretch length diameter
length

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
Minimum Maximum outer
Working Journe Maximum Connectio
Type compression diameter of dust
bore y stretch length n form
length cover

Two-way Upper pin

φ45 250 675±3 425±3 φ75
acting cylinder lower pin

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 Suspension maintenance manual
2.2. Structure

Serial Serial
Part Name Part Name
number number

1 Frame 6 Upper reaction rod assembly

2 Intermediate axle assembly 7 Lower reaction rod assembly

3 Rear axle assembly 8 Air suspension large bracket

4 Air spring bracket 9 Lateral 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.

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 Suspension maintenance manual
2.4 Check and adjust on board
2.4.1 Maintenance standard

Unit: mm
Maintenance items Standard values Correction methods

Difference between the distance from the Less than 5 Adjustments

left and right bridges to the rear axle

2.4.2 Tightening torque

Unit：N•m
Tightened part Tightening torque

Lower reaction bolt 600±100

2.5 Air spring bracket mounting hole spacing

2.5.1 Maintenance standard

Standard values(Inside [] is the Correction

Maintenance projects Code name
basic size) methods

Middle bridge air spring bracket arm

L1 [780]777.5~782.5 Adjustments
front side mounting hole distance

Middle bridge air spring bracket arm

L2 [780]777.5~782.5 Adjustments
rear side mounting hole distance

Rear axle air spring bracket arm front

L3 [780]777.5~782.5 Adjustments
side mounting hole distance

Rear air spring bracket arm front side

L4 [780]777.5~782.5 Adjustments
mounting hole distance

2.5.2 Tightening torque

Screwed parts Tightening torque

A nut for a u-bolt 700±50

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 Suspension maintenance manual
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
★The wheel block should be fastened to prevent the car 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

Serial Serial
Part Name Part Name
number number

1 Hexagon flange bolt thick rod (standard 39 Rubber joint assembly of rear lower

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 Suspension maintenance manual
type) reaction rod

Transverse stabilizer bar bracket with

2 40 Axle front air spring assembly
bushing assembly

Upper cover plate assembly - air

3 41 Large bracket - air suspension
suspension

Hexagon flange bolt thick rod (standard Hex socket head bolt
4 42
type) SPL Hexagon small flange locknut

5 Hexagon head flange bolt 43 Axle front air spring assembly

Front lower reaction rod with rubber

6 Reaction bar on front balance suspension 44
joint assembly

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

Hex socket 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

Hexagon flange bolt thick rod (standard

12 50 Cover - stabilizer bar
type)

Upper cover plate assembly - air

13 51 Rear transverse stabilizer bar assembly
suspension

Hexagon flange bolt thick rod (standard

14 type) 52 Drive axle rear air spring assembly

SPL Hexagon small flange locknut

Upper cover plate assembly - air

15 53 Stabilizer arm assembly
suspension

Hexagon flange bolt thick rod (standard

16 type) 54 Nut, spring washer

SPL Hexagon small flange locknut

Hex socket head bolt

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

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 Suspension maintenance manual
Leaf spring fifth piece and clamp
18 Upper bracket - rear shock absorber 56
assembly

19 Rear shock absorber assembly 57 Bracket-rear leaf spring

Hexagon flange bolt thick rod (standard

20 58 Adapter seat-air spring
type)

Rubber joint assembly for rear upper

21 59 Large washer
reaction rod

22 Rear upper reaction rod 60 Hexagon flange bolt thick rod (standard)

23 Hexagon head flange bolt 61 Height sensor assembly

Hexagon flange bolt thick rod (standard

24 62 Assembling bolt
type)

Upper cover plate assembly - air

25 63 Axle front air spring assembly
suspension

Hexagon flange bolt thick rod (standard

26 64 Adapter seat-air spring
type)

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

Rear leaf spring fifth piece and clamp

28 66 Spring washer
assembly

Hexagon flange bolt thick rod (standard

29 Bracket-rear leaf spring 67
type)

30 Stabilizer arm assembly 68 Support bracket-lifting 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)

36 Hex socket head bolt 74 Big support

Right arm with locating pin assembly -

37 75 SPL Hexagon small flange locknut
air spring

38 Double-end stud

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 Suspension maintenance manual
2.7.1 Tightening torque

Unit:N•m
Screwed parts 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 430±80

stabilizer bar)

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 600±100
reaction rod)

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

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

bar)

SPLhexagon small flange face lock nut(fastening on the 900±100

reaction bar large end)

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

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

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

bracket)

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；

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；

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 Suspension maintenance manual
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.

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 Suspension maintenance manual
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.
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.

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

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Suspension maintenance manual
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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