JAC HFC4DA1-2C engine. Instruction - part 33

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Instruction Transmission

Transmission

Transmission

Transmission

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Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

Exploded

Exploded

Exploded

Exploded View

View

View

View of

of

of

of Housing

Housing

Housing

Housing Assembly

Assembly

Assembly

Assembly

S/N

Name

Qty.

1

Flexible shaft bracket assembly

1

2

Liner

1

3

Housing

1

4

Side cover liner

1

5

Side cover of transmission

1

6

Side cover bolt

6

7

Oil drain plug assembly

1

 

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Instruction Transmission

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Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

Exploded

Exploded

Exploded

Exploded View

View

View

View of

of

of

of Shift

Shift

Shift

Shift Fork

Fork

Fork

Fork Assembly

Assembly

Assembly

Assembly

S/N

Name

Qty.

S/N

Name

Qty.

1

5th/reverse gear shift block

1

9

1st/2nd gear shift fork shaft

1

2

5th/reverse gear shift fork shaft

1

10

1st/2nd gear shift block

1

3

5th/reverse gear shift fork

1

11

Spring pin

6

4

Lock ball spring

2

12

Interlocking lifting pin

1

5

3rd/4th gear shift fork

1

13

Steel ball

7

6

3rd/4th gear shift fork shaft

1

14

Lock ball spring

1

7

3rd/4th gear shift block

1

15

Spring pin

5

8

1st/2nd gear shift fork

1

 

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Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

Exploded

Exploded

Exploded

Exploded View

View

View

View of

of

of

of Transmission

Transmission

Transmission

Transmission Front

Front

Front

Front Cover

Cover

Cover

Cover Assembly

Assembly

Assembly

Assembly

S/N

Name

S/N

Name

Qty.

1

Clutch housing

7

Spring washer

2

Release bearing

8

Flat washer

1

3

Input shaft front cap

9

Release fork assembly

1

4

Oil seal

10

Release fork shield

1

5

Hexagonal socket head cap screw

11

Ball joint bracket

1

6

Bolt (Clutch housing)

 

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Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

Transmission

Transmission

Transmission

Transmission Assembly

Assembly

Assembly

Assembly Diagram

Diagram

Diagram

Diagram

 

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Removal/Installation

Removal/Installation

Removal/Installation

Removal/Installation (Continued)

(Continued)

(Continued)

(Continued)

Transmission

Transmission

Transmission

Transmission

Installation
1.

Place transmission housing onto a clean cardboard.

2.

Install reverse gear and reverse gear shaft onto
transmission housing.

3.

Install side cover and reverse gear shaft pin of
transmission in place and tighten to the specified
torque.

4.

Install

transmission

countershaft

into

the

transmission housing.

 

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Removal/Installation

Removal/Installation

Removal/Installation

Removal/Installation (Continued)

(Continued)

(Continued)

(Continued)

Transmission

Transmission

Transmission

Transmission

5.

Install the fixed circlip of 5

th

driving gear of

transmission countershaft in place.

6.

Install

output

shaft

of

transmission

into

transmission housing.

7.

Install guide bearing of input shaft of transmission
in place.

8.

Install shifting mechanism assembly.

�

Maintain each gear and synchronizer at neutral

position.

�

Install interlocking steel ball into transmission

housing.

�

Install

gear

shift

shaft

into

transmission

housing gently.

 

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Removal/Installation

Removal/Installation

Removal/Installation

Removal/Installation (Continued)

(Continued)

(Continued)

(Continued)

Transmission

Transmission

Transmission

Transmission

9.

Install gear shift control mechanism assembly.

�

Install the self-locking device of gear shift
control mechanism in place.

10. Knock the input shaft gently into transmission.

Attention:

During the installation of input shaft, use rubber

hammer to knock gently

on symmetric

position on input shaft support bearing.

�

Install inside and outside circlips into input
shaft of transmission.

�

Install

the

countershaft

bearing

into

transmission. Please notice the mounting
direction of both side bearing inner rings, with
the one without ledge facing inward of
transmission. During installation, use hammer
to knock on transmission bearing gently and
evenly into transmission housing.

11. Install shifting mechanism assembly.

�

Maintain each gear and synchronizer at neutral

position.

�

Install interlocking steel ball into transmission

housing.

�

Install

gear

shift

shaft

into

transmission

housing gently.

12. Install gear shift control mechanism assembly.

Install the self-locking device of gear shift control
mechanism in place.

 

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Removal/Installation

Removal/Installation

Removal/Installation

Removal/Installation (Continued)

(Continued)

(Continued)

(Continued)

Transmission

Transmission

Transmission

Transmission

13. Install top cover of transmission.

Maintain gear shift control mechanism and gear
shift shaft at reverse gear position.

14. Install gear shift control mechanism onto the top

cover of transmission.

Attention:

Attention:

Attention:

Attention:

In order to avoid deformation during installation of
transmission cover, please tighten bolts on middle
part first and then bolts on both sides in symmetry.
(Check for normal gear shifting after installation)

15. Assemble

clutch

housing

onto

transmission

housing.

Tighten outer bolts and front cover mounting bolts of

input shaft. Please tighten bolts on middle part first
and then bolts on both sides or tighten diagonally.

16. Tighten output shaft flange of transmission to the

specified torque.

 

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Maintenance

Maintenance

Maintenance

Maintenance Parameters

Parameters

Parameters

Parameters

Tightening

Tightening

Tightening

Tightening torque

torque

torque

torque

Position

Technical Requirement (N.m)

Connection between clutch housing and transmission housing

68.6～93.2

Reversing lamp switch

29.4～39.2

Rear cover, transmission cover bolts

25～35

Bracket bolt

25～35

Side cover bolt

14～24.5

Vent plug

10.8～18.6

Oil filler plug and oil drain plug

39.2～58.8

Output shaft nut

160～210

Gear shift shaft dowel hole bolt

9.8～14.7

Odometer shaft sleeve

9.8～14.7

Release fork ball joint support

30～42

Input shaft front cap

9.8～14.7

Main technical parameters

Type

Five forward gears and one reverse gear

Control type

Remote control

Rated input torque

300N.m

Assembly mass

About 78Kg

Speed ratio

Gear position

Speed ratio

1

st

gear

4.717

2

nd

gear

2.513

3

rd

gear

1.679

4

th

gear

1.00

5

th

gear

0.784

Reverse gear

4.497

 

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Instruction Transmission

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Transmission

Transmission

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Care

Care

Care

Care and

and

and

and maintenance

maintenance

maintenance

maintenance

Transmission

Transmission

Transmission

Transmission maintenance

maintenance

maintenance

maintenance

1.

Transmission operation and maintenance should be conducted in accordance with application and maintenance
requirements for commercial vehicles, which are generally divided into three technical maintenance stages.

2.

Check, change (or add) transmission oil regularly.

Regular Inspection and Maintenance Schedule for Transmission
Mileage and time (by the month) are both indicated for each item, whichever occurs first.
○ Check point, tighten or adjust; ★ Change lube oil

Item

Service interval (based on odometer reading or number of months, which occurs first)

Number of months

－

3

6

12

18

24

30

36

42

48

54

Odometer reading×1000km

1

5

10

20

30

40

50

60

70

80

90

Transmission inside inspection

Check gear oil level inside transmission

○

○

○

○

○

Change

gear

oil

inside

transmission

Normal

service

condition

★

★

★

★

★

Severe

service

condition

★

★

★

★

★

★

★

★

Other inspections

Note: “Severe service condition” includes items listed below:
1.

Running in dusty areas or frequently exposed in salty atmosphere or saline water.

2.

Running on bumpy, water-logging roads or on mountain road.

3.

Running in cold areas.

4.

Engine idling for a long time or frequent short distance running in cold seasons.

5.

Frequent application of brakes and emergency brake.

6.

Towing vehicle.

7.

Under high temperature over 32℃, the time of vehicle running slowly in congested urban areas exceeding 50%
of total running time.

8.

Under high temperature over 30℃, the time of vehicle running at high speed over 120km/h exceeding 50% of
total running time.

9.

Overloading.

Lubrication and seal

Item

Item

Item

Item

Lube

Lube

Lube

Lube Oil/Sealant

Oil/Sealant

Oil/Sealant

Oil/Sealant

Qty.

Qty.

Qty.

Qty.

Transmission gear oil

Gear oil

In summer 80W/90 GL-4

In winter 75W/90 GL-4

2.7L

Release bearing bore of transmission

Grease

Adequate

Transmission oil seal

Grease

Adequate

Mating face between transmission housing and clutch housing

TONSAN®1596F

Adequate

Mating face between transmission housing and rear cover

TONSAN®1596F

Adequate

 

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BR

BR

BR Brake

Brake

Brake

Brake System

System

System

System

- 45-

Brake

Brake

Brake

Brake System

System

System

System

Applied models: SUNRAY products manufactured by JAC

Subject

Page

Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

Brake System................................................................................................................................................................. 46

Explosive View......................................................................................................................................................... 46
Introduction of Brake................................................................................................................................................47

Diagnosis

Diagnosis

Diagnosis

Diagnosis and

and

and

and Testing

Testing

Testing

Testing

Brake System................................................................................................................................................................. 49

Inspection and confirmation..................................................................................................................................... 52
Fault Symptom Table................................................................................................................................................53

Removal/Installation

Removal/Installation

Removal/Installation

Removal/Installation

Removal/installation of brake disc........................................................................................................................... 50
Removal/installation of brake caliper assembly.......................................................................................................54
Removal/installation of rear wheel brake shoe........................................................................................................ 56
Parking brake adjustment......................................................................................................................................... 59
Removal/installation of parking brake lever............................................................................................................ 60
Removal/installation of parking brake cable............................................................................................................61
Replacement of parking brake cable........................................................................................................................ 62
Removal/installation of brake pedal.........................................................................................................................63
Removal/installation of brake master cylinder.........................................................................................................65
Removal/installation of vacuum pump.................................................................................................................... 66
Removal/installation of vacuum booster..................................................................................................................68
Air bleeding for hydraulic pressure brake system....................................................................................................71

 

BR

BR

BR

BR Brake

Brake

Brake

Brake System

System

System

System

- 46 -

Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

SUNRAY vehicles’ brake system adopts cross type brake line and the front disc/rear drum brake type.

1．Brake master cylinder

2. Hydraulic distribution valve

 

BR

BR

BR

BR Brake

Brake

Brake

Brake System

System

System

System

- 47-

Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

Operating

Operating

Operating

Operating principle

principle

principle

principle

Brake

Brake

Brake

Brake fluid

fluid

fluid

fluid

Inspection

Inspection

Inspection

Inspection of

of

of

of brake

brake

brake

brake fluid

fluid

fluid

fluid level:

level:

level:

level:

1.

Check if the brake fluid level in oil reservoir is
within the specified range (between MAX and
MIN signs). In case of too low fluid level, please
check oil reservoir periphery and brake system for
any leak.

2.

Start the vehicle with parking brake lever released
to observe whether the brake warning lamp goes
out. If not, please check the parking brake switch
and brake fluid level switch for any fault.

Brake

Brake

Brake

Brake master

master

master

master cylinder

cylinder

cylinder

cylinder

On-vehicle

On-vehicle

On-vehicle

On-vehicle inspection:

inspection:

inspection:

inspection:

Check mounting surfaces of master cylinder and oil
reservoir, as well as brake pipe connectors for any leak.
Instruction and Operation
Inspection

Inspection

Inspection

Inspection of

of

of

of vacuum

vacuum

vacuum

vacuum booster

booster

booster

booster

1.

Operation inspection
Shut down the engine and repeatedly depress the
brake pedal for several times to make the vacuum
inside

the

vacuum

booster

equivalent

to

atmospheric

pressure.

With

the

brake

pedal

depressed to the end and engine started, check if
the clearance between brake pedal and floor
decreases once the vacuum up to the standard
degree.

Attention:
Please depress the brake pedal with an interval of 5
seconds.

2.

Air tightness inspection

Start the engine and let it idling for 1 minute, and
shut down the engine once the vacuum established
in the vacuum booster. Depress the brake pedal
normally to remove the vacuum.
Please check if the clearance between brake pedal
and floor increases gradually.
Depress the brake pedal with engine running and
then hold the brake pedal depressed to realize
flameout. Please check if there is any change in
pedal travel after holding it for 30 seconds.

Front

Front

Front

Front disc

disc

disc

disc brake

brake

brake

brake caliper

caliper

caliper

caliper

On-vehicle

On-vehicle

On-vehicle

On-vehicle inspection:

inspection:

inspection:

inspection:

1.

Check brake shoes for any wear.
Attention:

Attention:

Attention:

Attention:

Standard thickness: 12mm
Wear limit thickness: 2mm

Inspection

Inspection

Inspection

Inspection of

of

of

of brake

brake

brake

brake disc:

disc:

disc:

disc:

1.

Visual inspection
Check brake disc surface for uneven abrasion,
crack or sever damage. If any, please replace the
brake disc.

2.

Inspection of runout
①

Fix the brake disc onto the wheel hub.

Attention:

Attention:

Attention:

Attention:

Before measurement, please ensure proper axial
clearance of wheel bearing.

MAX

MAX

MAX

MAX

MIN

MIN

MIN

MIN

Good

Poor

1

st

2

nd

3

rd

 

BR

BR

BR

BR Brake

Brake

Brake

Brake System

System

System

System

- 48 -

②

Check the runout with dial indicator. (It is
preferable to conduct measurement at points
10mm distant from the disc edge)
Runout limit: 0.05mm

③

If the disc runout exceeds the specified value,
please replace or reprocess it accordingly.

3.

Thickness inspection
Check

the

thickness

of brake

disc

with

a

micrometer.
If the thickness is less than the wear limit, please
replace the brake disc.

Standard thickness: 24.3mm
Wear limit: 22.3mm

 

BR

BR

BR

BR Brake

Brake

Brake

Brake System

System

System

System

- 49-

Fault

Fault

Fault

Fault Diagnosis

Diagnosis

Diagnosis

Diagnosis

Common

Common

Common

Common fault

fault

fault

fault diagnosis

diagnosis

diagnosis

diagnosis table

table

table

table

Fault Symptom

Possible Cause

Solution

Vehicle pulled to one side

when braking

Insufficient left/right tire pressure

Adjust

Improper front wheel alignment

Adjust

Poor contact of brake shoe

Adjust

Grease or oil existed on brake shoe surface

Replace

Improper installation of brake wheel cylinder

Adjust

Failure of auto-regulating mechanism

Adjust

Insufficient brake force

Low level or contamination of brake fluid

Replenish or change

Air existed in brake system

Bleed air out of system

Failure of vacuum booster

Adjust

Poor contact of brake shoe

Adjust

Grease or oil existed on brake shoe surface

Replace

Failure of auto-regulating mechanism

Adjust

Overheating of brake rotary parts due to sluggish of brake shoe

Adjust

Restriction of brake line

Adjust

Pedal travel increase

(decrease of clearance

between pedal and floor)

Air existed in brake system

Bleed air out of system

Leak of brake fluid

Adjust

Failure of auto-regulating mechanism

Adjust

Excessive clearance between pushrod and brake master cylinder

Adjust

Brake hysteresis

Parking brake not fully released

Release

Improper adjustment of parking brake

Adjust

Wear of brake pedal return spring

Replace

Restriction of return opening of brake master cylinder

Adjust

Insufficient lubrication of sliding parts

Lubricate

Defective check valve or piston return spring of brake master cylinder

Replace

Insufficient clearance between pushrod and brake master cylinder

Adjust

Insufficient parking braking

Damage of rear brake shoe

Replace

Grease or oil existed on rear brake shoe surface

Replace

Parking brake cable stuck

Adjust

Failure of auto-regulating mechanism

Adjust

Excessive travel of parking brake handle

Adjust

 

BR

BR

BR

BR Brake

Brake

Brake

Brake System

System

System

System

- 50 -

Removal/Installation

Removal/Installation

Removal/Installation

Removal/Installation

Front

Front

Front

Front brake

brake

brake

brake disc

disc

disc

disc

Removal
1.

Have the vehicle lifted and remove the front wheel.

2.

Remove the brake hose from the shock absorber.

Note:

Note:

Note:

Note:

Loosen the brake caliper to certain degree ready
for removal instead of removing it completely.

3.

Remove the brake caliper.

Hang up the brake caliper properly in order to

avoid damage of brake hose.

Caution:

Caution:

Caution:

Caution:

Bearing preload adjusting nut is of right hand
thread.

4.

Remove the brake disc assembly:

�

Remove the dust cover.

�

Remove the split pin and nut retainer.

�

Loosen the adjusting nut of wheel bearing.

�

Remover the brake disc assembly.

5.

Remove the wheel hub from the wheel disc.
Bend the lock lug on the set bolt down.

6.

Clean the contact surface between wheel hub and
disc.