Foton Series Light Bus. Instruction — part 11

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Symptoms and causes

Removing procedures

Higher charging

current, burn out

bulb often

(1) Regulated voltage is too high.

(2) Regulator magnetic coil is de-welded to

lose regulation.

(1) Adjust voltage to specification.

(2) Check and repair coil and re-weld.

9.11 Lower battery volume, higher self-discharging

Symptoms and causes

Removing procedures

Hard engine startup

due to lower battery

volume

(1) Lower battery fluid level.

(2) Short circuit among battery plates.

(3) Plates are sulphurized.

(4) Poor contacting at circuit connections,too

much oxide on terminals. Insufficient charging.

(1) Fill in distilled water or diluted

sulfuric acid (concentration 1.1) as

specified.

(2) Remove sediments or change battery

fluid.

(3) Repeatedly recharge to remove

sulphurization.

(4) Make the connection firm, remove

oxide and apply Vaseline on terminals.

Larger battery

self-discharging

(1) Impurities in battery fluid.

(2) Short circuit on battery outside lead.

(3) Fluid overflowing from battery, connect

positive / negative poles to short circuit.

(4) Heavy shedding, damaged separator

plates and warped plates make short circuit.

(1) Add battery fluid formulated with pure

sulfuric acid and distilled water as

specified.

(2) Locate short circuit and remove.

(3) Clean battery surface and terminals

with soda water or warm water, be sure

no water is entering battery.

(4) Repair or replace battery.

● Cautions:

(1) The gas released from battery is easy to be ignited by sparks, so there should be no lighted fire presenting

during battery’s check and service. Do not let battery fluid contact skin and cloth. Wear goggles while servicing a

battery.

(2) Never short circuit two battery terminals, or it may lead to battery overheating even explosion.

(3) While dismounting or mounting electrical equipments, remove first the negative (ground) cable from

terminal. But for replacing light bulbs, cutting off relating switch would be ok.

(4) When removing a battery, remove negative cable first then positive cable. Untie battery bracket to life out

battery. Operate in reverse sequence to mount a battery.

9.12 Failure cold-start preheating system

Symptoms and causes

Removing procedures

Turn ignition key to “START”, engine stalls after flash indicator

has blinked 30 seconds at a frequency of 4 times per second.

The cause may be burnt fuse or short circuit on glow plug “P”

(normal glow plug resistance is about 2Ω), or solenoid “D” fuse

is burnt. Fuse damage or loose wire connection may also be the

causes.

Check circuit of cold start device or replace

damaged parts.

Chapter 9 Diesel Engine Faults and Troubleshooting

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Symptoms and causes

Removing procedures

Turn ignition key to “START”, engine stalls after flash indicator

has blinked 60 seconds at a frequency of 4 times per second.

This may be caused by relay contacts inside controller that

control FGK output haves not closed due to damaged controller

or lower battery voltage (lower than 9V).

Replace controller or charge battery to

specification.

Glow plug does not ignite during normal preheating. The cause

may be blocked fuel pipe / plug fuel feeder or damaged solenoid

parts.

Check fuel pipe, replace damaged parts.

After whole preheating process has completed (ignition key on

“START”):

（1）Indicator goes off after it has blinked (quickly) for 60

seconds at a frequency of 4 times per second. This may be

caused by stuck MV output relay contacts.

（2）Indicator keeps blinking at a frequency of 4 times per

second This may be caused by stuck FCK output relay contacts.

（3）Indicator goes off after it has blinked (quickly) for 30

seconds at a frequency of 4 times per second. Coolant

temperature sensor RT is disconnected or poor contacting of RT

harness may cause this.

（1）Cut off power and replace controller.

（2）Replace controller.

（3）Replace controller.

When coolant temperature is below 15℃, turn ignition switch to

“START” will not lit indicator. Damaged indicator clip or

controller, or poor harness contacting may cause this.

Check harness first, if indicator keeps off,

replace indicator. Replace controller if

replaced indicator still does not lit.

9.13 Water pump electro-magnetic fan clutch faults

No.

Symptoms and causes

Removing procedures

Power lead is

disconnected or

voltage is too low

Check power lead (from alternator terminal B to clutch) for

continuity and ground. Check the plug connecting

temperature control switch and clutch for tightness; check

battery voltage, and if alternator operates well.

1

Fan does not

work, higher

engine

coolant

temperature

Control switch is

failure.

Unplug clutch lead from switch, connect clutch lead to

alternator terminal “B” with a wire (can not keep connection

for long). Listen to any clutching sound from clutch. If

clutch is fine and no other faults are found after above

checks, the cause must be temperature control switch.

Replace switch.

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No.

Symptoms and causes

Removing procedures

Excessive clutch

clutching clearance

If there is no clutching sound from clutch, measure with a

feeler the clearance between clutch suction disc and the

pulley, adjust clearance to 0.5～0.8mm.

Clutch is failure

In the events clutch still does not work after clutching

clearance, power supply connection and switch all have

been checked and adjusted, remove water pump belt, turn

with hand the pulley and fan to see if there are grabbing. If

things are normal, make adjustment with the 3 bolts on front

end of clutch fan retaining plate, pressing suction firmly on

pulley. This will make fan and water pump synchronizing.

Coolant temperature is

too low.

Measure coolant with a water thermometer to see whether

coolant reaches the working temperature 85±2℃.

Power lead has not

connected firmly.

Tighten the connection.

2

Fan clutch

works

intermittently

Coolant short in

radiator

Check level in radiator timely and add coolant or antifreeze.

Gasket leaks.

If coolant leakage is seen at connecting section between

water pump and engine, damaged water pump gasket is the

cause. Replace water pump gasket.

3

Water pump

leaks

Coolant sealing leaks.

Check leaking spot. If coolant comes from water pump

overflow hole under pulley, damaged water seal is the cause.

Replace water pump (but slow dripping from overflow hole

is normal).

Clutch noise

4

Abnormal

sound from

assemblies

Water pump noise

（1）Check if clearance between suction plate pulleys is too

small. Adjust to specification.

（2）Voltage is too low, clutching torque is insufficient.

（3）Loosen belt and turn pulley and fan to check if there are

grabbing, swinging and rubbing. Replace assembly if any

Coolant temperature

sensor is failure.

5

Fan is

activated only

after the hand

of coolant

temperature

meter reaches

red zone

Clutch temperature

control switch is too

hot.

Measure coolant temperature in radiator with a water

thermometer. If it works only when coolant temperature is

over 90℃, either temperature control switch or sensor is

failure.

Chapter 9 Diesel Engine Faults and Troubleshooting

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No.

Symptoms and causes

Removing procedures

● Notes:

1. Fault- removing procedures and requirements to replacement and mounting-- temperature control

switch:

(1) Remove temperature control switch, connect its two leads to a voltmeter. Put switch in water

under heating. Switch is well if voltmeter indicates continuity at 83±2℃. ( As thermometer

error is concerned, switch is considered well even at 80～87℃.

(2) Temperature control switch case is thin, dismounting/mounting torque should not exceed 20N.m.

Otherwise it might get distort, cannot work properly.

2. In the event engine is overheated and clutch is failure while no spare parts at hand, you can set

clutching clearance to zero and fix it via 3 adjusting bolts on fan retaining plate. Let fan run

synchronizing with pulley. Bring the problem to service station quickly.

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Chapter 10 Chassis Structure and Service

10.1 Clutch

10.1.1 Main Technical Parameters of Clutch

Main Technical Parameters of Clutch

Sn

Description

Data

1

Engine Model

486ZQB

YC4F90-21

491EQ1

2

Type

Single plate, dry, diaphragm spring clutch, hydraulic operation

Inner diameter

Φ160

Φ150

Φ150

3

Clutch plate size
（mm）

Outer diameter

Φ240

Φ235

Φ236

4

Shock absorber

Corrugated spring plus damping spring

5

Pressure plate pressing force（N）

4000

5500

4900

6

Max driving torque（N-m）

202

281

255

7

Type of control mechanism

Hydraulic operation

8

Release master cylinder×travel

(mm)

Φ15.875×34

Φ15.875×30

Φ15.875 ×34

9

Slave cylinder inner diameter.

× travel (mm)

Φ19 × 24

Φ19.5 × 29

Φ20.6 × 35

10

Clutch pedal height (mm)

170±3

11

Free travel of clutch pedal (mm)

5~15

12

Maximum radial circle run-out of

flywheel

0.2

13

Max run-out of driven plate (mm)

0.8

14

Planeness of release finger tip of

diaphragm spring

0.5

10.1.2 Structure Overview

Clutch connects engine and transmission, it transmits and cuts off power connection between these two. It is

mainly used to start up vehicle, help gear-shifting and avoid overload on transmission line. BJ6536 series light

buss adopt diaphragm spring clutch. The clutch transfers engine power through frictions at drive and driven parts,

and cuts off power with release mechanism. The clutch is operated by clutch operating mechanism. The operation

mechanism has the characteristics of low friction resistance, high transmitting efficiency and smooth-clutching.

The clutch mainly consists of clutch pedal, master cylinder, slave cylinder, booster and oil pipe.

Chapter 10 Chassis Structure and Service

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1. Diaphragm spring clutch (Figure 10-1-1)

Figure 10-1-1 Diaphragm Spring Clutch

1.hook plate- release fork return spring 2-return spring 3-hood 4-return spring 5-release bearing socket assembly 6-release socket

7-release bearing 8-bolt 9-clutch driven plate assembly 10- corrugated spring leaf rivet 11-friction plate 12-FR/RR damping disc with

case assembly 13-driven plate assembly rivet 14- corrugated leaf/FR damping disc assembly 15-corrugated spring leaf 16- FR

damping disc 17-large/small damping spring 18-damping plate 19-clutch disc case 20-damping spring washer 21-damping spring

washer 22-RR damping disc 23-hollow rivet 24-clutch pressure plate and cover assembly 25-flat rivet 26-clutch rear disc

27-rear disc connecting plate 28-clutch cover and diaphragm spring assembly 29-pressure plate transmitting plate 30-clutch cover

31-diaphragm spring rivet 32- diaphragm spring 33-clutch release fork 34-bracket spring 35-circular bracket 36-bolt

37-dust boot 38-clutch housing

Diaphragm spring clutch is a kind of advanced clutch, composed by pressure plate and cover assembly (24),

driven plate assembly (9) and release mechanism. By using a disc diaphragm spring (32), clutch rear disc and

cover assembly is mounted on clutch cover (30) by attaching its big end with nine rivets (31). (Its small end

Slave cylinder assembly

Slave cylinder assbly, RH on gasoline engine

and LH on diesel engine

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contacts release bearing). A 2-step torsion damper and an auto compensative damper are mounted on driven plate.

A corrugated spring leaf (15) is mounted on front damping disc (16), two friction plates (11) is riveted on both

sides of corrugated spring leaf. Clutch disc hub (19) (with involutes spline) mounts on transmission input shaft.

The clutch driven disc assembly that slides on input shaft spline

is pressed in between flywheel and clutch

pressure disc (26). The friction force made by pressure disc transmits engine power to transmission via FR/RR

damping discs (16, 22) and through damping spring (17) / clutch disc hub.

Clutch pressure disc assembly releases away from driven plate assembly by means of releasing mechanism.

When clutch pedal is depressed, the force presses onto small end of diaphragm spring via release fork (8) through

release bearing assembly (5), thus detaches the clutch; while pedal is released, pressure disc assembly, by using

the returning force of diaphragm spring, presses on driven plate assembly to engage the clutch.

10.1.3 Check and Repair

Check each part after clutch and its operating mechanism have been removed from vehicle. Carry out

necessary maintenance and repair.

1. Check and repair -- clutch assembly

(1) Clutch driven plate assembly
①Wear on friction plate. Measure 2 rivets’ depth on driven plate (from friction plate surface to rivet head, “t”

in figure 10-1-5). If wear amount is equal or less than limit (table 10-1-1), operator should replace driven plate

assembly or fix friction plate again with rivets. Remount rivet if it is loosening. Replace two friction plates at the

same time.

Figure 10-1-5 Measure rivet depth Figure 10-1-6 Axial runout check -clutch driven plate

②Check axial runout of clutch driven plate. Measure at the spot 2.5mm from driven plate edge (figure

10-1-2), if results exceed limits (table 10-1-2), driven plate should be adjusted or replaced.

Table 10-1-1 Rivet Depth (t)

Description

Standard (t)

Limit (t)

Driven plate of diaphragm spring clutch

1.3mm

0.3mm

Table 10-1-2 Run-out

description

Measuring point

Limit

Driven plate — diaphragm spring clutch

2.5mm from the edge

Less than 0.8mm

(2)

Clutch diaphragm spring

On the connection spot of diaphragm spring release finger tip with release bearing, if wear exceeds 1mm,

repair should be performed. If there are permanent distortion or crack on spring, diaphragm spring together with

Chapter 10 Chassis Structure and Service

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clutch cover rivets should be replaced.

(3)

Clutch pressure plate

Check pressure plate’s working surface. Planish

surface if wear exceeds 0.5mm or planeness exceeds

0.12mm. The required harshness is Ra0.8μm, general grinding limit is less than 1.5mm. Static balance test

should be carried out after grinding, and its unbalance amount should not be more than 28g.cm. If pressure plate

thickness is 1.5mm less than standard thickness after repair, the plate should be replaced.

2.

Check and repair — clutch release mechanism parts

（1）Clutch housing. Check case for crack and distortion. Replace if necessary.
（2）Clutch release bearing. Clean bearing race, check release bearing for wear or damage. Its rotation should

be smooth without abnormal noise. Otherwise replace it.

（3）Release sleeve and fork. Check release sleeve upper part and release fork contacting face for wear or

damage. Repair any uneven wear, and replace parts if wear exceeds 1mm.

3.

Check and repair — clutch operating mechanism

（1）Clutch pedal mechanism. Check for wears on all fitting surface on rotating parts such as shaft, pin hole

and sleeve. Replace part if necessary.

（2）Clutch master cylinder
① Check master cylinder tube and piston for wear. If cylinder tube cylindricality discrepancy exceeds

0.025mm, repair it till the value is not more than 0.01mm. Replace part if wear or damage become serious. Fitting

standard (cylinder tube and piston). See table 10-1-3

Table 10-1-3

Fitting standard-master cylinder and piston (mm)

Description

Standard

Limit

Piston diameters

φ15.875H9/e8

φ15.875 (0, -0.032)

Fitting clearance

0.02~0.06

0.12

② Check master cylinder return spring for rupture, damage and elastic force. Replace it if necessary.

(3) Check slave cylinder tube and piston for wear. If cylinder tube cylindricality discrepancy exceeds

0.025mm, repair it till the value is not more than 0.01mm. Replace part if wear or damage become serious. Fitting

standard (cylinder tube and piston). See table 10-1-4.

Table 10-1-4

Fitting standard -- slave cylinder and piston (mm)

Description

Standard

Limit

Slave cylinder piston diameters

φ20.64 H9/e8

(φ20.64 0, -0.040)

--

Fitting clearance

0.02~0.06

0.12

10.1.4 Reassembly and Adjustment

After having checked and repaired clutch parts as per specification, reassemble the clutch and make

adjustment again.

1. Locate spline hole on clutch disk hub, check run out tolerance of driven plate assembly (Figure 10-1-6).

Measure at the spot 2.5mm from driven plate edge, if results exceed 0.8mm, driven plate should be adjusted or

replaced.

2. Dynamic unbalance of clutch cover assembly should not exceed 28 gram-cm; dynamic unbalance of

driven plate assembly should not exceed 28 gram-cm.

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3. Before mounting clutch assembly on engine, clean flywheel friction face, there should be no oil dirt on

fitting surface of clutch friction plate. Meanwhile, apply a thin layer of lubricant oil on fitting surfaces of release

bearing sleeve, release fork, ball support of release fork and ball nut of push rod.

4. When to reassemble clutch, operator should first mount adjusted clutch driven plate assembly and then

cover assembly on flywheel face (be sure to set the short end of clutch plate hub in driven plate assembly to the

front). In order to make these two assemblies and flywheel concentric, one should insert a piece of spline

bar (may

use transmission input shaft as a tool) into flywheel pilot bearing to locate driven plate assembly, and put pressure

plate and cover assembly in place by flywheel locating pin. Fix them with bolts

5. Reassembe and adjust of clutch controls

Reassembly:

(1) Reassemble and check master cylinder. Thoroughly clean parts before reassembly, and bath sealing

cups and rings in brake fluid. Be sure not to block oil holes on master cylinder inner wall and piston.

① Reassembly of master cylinder. Proceed in reverse order to disassembling.
② Check after reassembly.
▲ Piston cup of master cylinder should seal well. There should be no brake fluid weeping on it when

piston goes back and forth.

▲ Perform sealing test under an oil pressure of 13Mpa. Ensure no leakage occurs in 5 seconds.

(2) Reassemble and check slave cylinder. Thoroughly clean parts before reassembly, and bath sealing ring

and cup in brake fluid.

① Reassemble slave cylinder. Proceed in reverse order to disassembly.
② Check after reassembly.
▲ After reassembling, devices should operate freely without any restriction or grabbing.
▲ Perform sealing test under an fluid pressure of 13Mpa. Ensure no leakage occurs in 5 seconds.

(3) Reassemble clutch pipeline
① Proceed in reverse order to disassembly.
② During reassembly, keep oil pipe and connectors clean, clamp pipes and fasten the connectors. There

should be no restriction in pipeline or weeping at connectors.

(4) Reassemble clutch pedal mechanism
① To make sure all fitting surfaces of all pins, shaft and pinhole are clean. Apply a layer of thin lubrication

grease on them.

② Proceed in reverse order to disassembly.
③ After reassembly, the rotating components should be connected firmly and can move freely.
④ Install the reassembled clutch pedal mechanism onto the instrument panel and cabine floor and fix it

with connecting bolts.

Adjustment:
① Clutch pedal free travel. Free travel is the joint results made by the distance (i.e. release clearance)

between diaphragm spring release finger (or lever) end and release bearing, as well as distance between release

master cylinder pushing rod and piston. Adjust pedal free travel is in fact to adjust these two distances. Adjustment

should be made according to requirements.

a. Clutch release clearance adjustment. Change the length of slave cylinder push rod to adjust clearance.

Remove return spring between release fork and clutch housing, and loosen slave cylinder push rod locking

nuts. Turn push rod clockwise to attach ball nut with release fork, and turn ball nut backward 1-1.5 turns. Fasten

push rod locking nut, install release fork return spring. The clearance from release bearing side to diaphragm

spring release finger tip at this moment is 1.5～2.mm.

Chapter 10 Chassis Structure and Service

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b. Adjust clearance between master cylinder pushing rod and piston. Loosen locking nut on master cylinder

pusing rod, turn pushing rod counter clockwise till it touchs piston, turn pushing rod clockwise 3/4 turn, and then

fasten locking nut on pushing rod. The clearance should be 1mm.

② Clutch pedal height adjustment. While pedal has proper free travel, its high-low adjustment is made by

means of limiting screw. Method is to loosen locking nut on screw that mounted on pedal’s bracket, turn screw

clockwise. Pedal height increases as screw tread grows and lowers as tread diminishes. Keep adjusting till pedal’s

center face is 170±3mm from cab floor. Then tighten locking nut.

③ Bleed clutch pipeline system. In order to obtain normal operation for clutch hydraulic pressure

operating system, there should be no air in system fluid. To bleed the system needs two persons: one depresses

clutch pedal in the cab while the other peforms venting at slave cylinder. The bleeding procedures as follows:

a. Remove vent plug and hook up a plastic hose, place other end of hose in a see-through cup of suitable

size;

b. Fill up the cup with brake fluid. Be sure to keep adding fluid to the cup as bleeding is in progress to

maintain at least 2/3 cup of fluid all the time.

c. Unscrew vent plug for 1/2 turn, depress-release pedal many times to flood release master cylinder,

pipelines and slave cylinder;

d. Loosen vent plug, drain out fluid with air;.

e. Pedal moves downward while air fluid is being discharged. Fasten plug immediately at the moment pedal

almost lowers to its extreme position.

f. Repeat procedure “e” till there is no sign of bubbles in fluid. Then fasten vent screw plug finally, remove

hose and install screw cap.

10.1.5 Typical Faults and Elimination

1. Incomplete clutch release (see table 10-1-5).

Clutch can not cut off engine power output while pedal is depressed to floor, clutch then keeps running by

being dragged by engine. Incomplete release may lead to gear shock and shift difficulty.

Table 10-1-5 Incomplete clutch release—faults and Eliminations

Causes

Eliminations

1

Larger pedal free travel

1

Correct free travel

2

Uneven height—diaphragm release finger tip

2

Adjust height

3

Clutch driven plate warped

3

Adjust or replace

4

Broken clutch plate

4

Repair or replace

5

Loosened friction plate rivet

5

Mount rivet again

6

Transmission: worn-out front bearing makes

inputshaft incline.

6

Replace bearing

7

Clutch pressure plate warped

7

Grind or replace pressure plate

8

Release master/slave cylinder leakage

8

Replace piston cup or replace assembly

9

Air in brake fluid

9

Re-bleeding

10

Inadequate slave cylinder travel

Re-design to correct the travel

2. Clutch skidding ( see table 10-1-6).

Clutch driven plate skids when clutch pressure plate cannot press driven friction plate tightly on flywheel

surface. Depress acceleration pedal under heavy load will only make engine roaming rather than speeding up.

Minor slippery is hard to be noticed, but high temperature due to friction will burn out friction plates.

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Table 10-1-6 Clutch Skidding – faults and eliminations

Causes

Eliminations

1

Operating

mechanism

unadjusted

after

friction plate has worn

1

Readjust operating mechanism or replace

excessive worn friction plates

2

Clutch driven plate caught on inputshaft

spline, or release bearing stuck

2

Remove stuck

3

Weak or broken clutch diaphragm spring

3

Replace spring

4

Oil dirt on friction plate

4

Remove oil dirt

5

Shorter clutch pedal free travel

5

Adjust free travel to standard

3. Rough clutch engagement (see table 10-1-7).

Vehicle speed jumps up and down at startup and shifting, with forward-backward “shake” feeling.

Table 10-1-7 Rough clutch engagement – faults and elimninations

Causes

Eliminations

1

Driven plate wave plate—cracked or damaged

1

Replace parts or assbly

2

Driven plate distorted or uneven wear

2

Adjust or replace

3

Uneven wear on pressure plate or flywheel

3

Repair or replace

4

Uneven height on release fingers ends

4

Adjust to standard height

4. Abnormal sound from clutch ( see table 10-1-8).

“Click, click, click” sound is heard when transmission is at N gear and engine is running at idle. Abnormal

noise comes out when clutch pedal is depressed or released.

Table 10-1-8 Abnormal Sound from Clutch – faults and elminiations

Causes

Elminations

1

Driven connecting plate broken and pinot

loosened

1

Repair or replace

2

Release bearing’s return spring distorted,

broken, loosened

2

Repair to replace

3

Flywheel bolt loosened

3

Fasten or replace

4

Clutch release bearing worn, dirty, damaged

or short lubrication

4

Repair or replace

5

Worn-out

transmission

inputshaft

front

bearing or lubricant is short

5

Change or add grease

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10.2 Transmission

10.2.1 Main Technical Parameters of Transmission

Main Technical Parameters of Transmission

Sn

Description

Data

1

Matched model vehicle

With 483ZQB Tang

Gear ZSYO8

With BJ491EQ1

Tang Gear 5RYA4

With YC4F90-21

2

Type

Manual, fixed shaft, mechanical 5 gears OD type, synchronizer

meshing at all forward gears

3

Maximum output torque (N.m)

198

198

220

4

Center distance (mm)

72

72

72

1 gear

4.452

4．452

3.992

2 gear

2..619

2．619

2.15

3 gear

1..410

1．517

1.33

4 gear

1.000

1．000

1.000

5 gear

0.802

0．856

0.862

5

Drive

ratio at

each gear

Reverse gear

4.4725

3．578

3.6

6

Type of gear

Meshing bevel gear with lock ring inertia synchronizer

7

Lubricant

GL5, 85W/90

8

Lubricant volume (L)

2.0

2．4

2.6

9

Weight (kg)

36

41

40.75

10

Operating mechanism

Long distance manual manipulation for side cover

10.2.2 Structure Overview

Vehicle operates differently in different situations, such as it works during start-up, accelerating, decelerating,

driving at low/high speed, driving uphill, backing up, parking etc. These need vehicle’s traction and speed to be

changed in a larger range. But torque/speed output from current vehicle engine is too limited to meet this demand.

To compensate this, vehicle powertrain employs transmission. Transmission is used to change drive ratio to make

vehicle maneuvers like backward driving and power cut-off possible.

5RYA4 transmission is a three-shaft gear type with 5 forward gears and 1 reverse gear. It is connected to

clutch housing with bolts.

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Table 10-2-1 Transmission Assembly-1

Table 10-2-2 Transmission Assembly-2

1-Transmission assembly; 2-Bolt; 3-Clutch housing; 4,5-Dust boot; 6-Bolt; 7,8-Right reinforcing plate; 9-S type oil seal; 10-O

ring; 11-Driven gear bracket of odometer; 12-Driven gear circlip of odometer; 13-Driven gear of odometer; 14-Front housing;

15-Front housing gasket; 16-Front housing oil seal assembly; 17-Front bearing thrust ring of counter shaft; 18-Front bearing thrust

ring of counter shaft; 19-Thrust ring of input shaft bearing; 20-Sealing; 21-Housing; 22-Hexagon magnetic bolt (drain plug); 23-Rear

body dust boot; 24-Rear body oil seal assembly; 25-Rear body component; 26-Transmission cover component; 27-Bolt; 28-Nozzle;

29-Nozzle; 30-Intermiedate connecting plate component

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Figure 10-2-3 Intermediate Connecting Plate Component of Transmission-1

1-Input shaft subassembly; 2-Input snap ring; 3-Thrust ring of input shaft bearing; 4-Input shaft bearing; 5-Input component;

6-Needle bearing of input shaft; 7-Cynchronizer gear for 3rd, 4th, 5th gears; 8-Output shaft subassembly; 9-Front shaft snap ring of

intermediate separating shaft; 10-Front bearing thrust ring of countershaft; 11-Front bearing of countershaft; 12-Connecting gear of

countershaft; 13-Steel ball; 14-Rear bearing of countershaft; 15-Rear bearing thrust ring of countershaft; 16-Thrust washer of 5th

gear; 17-Intermiedate 5th gear needle bearing; 18-countershaft 5th gear component; 19-5th gear synchronizer slider; 20-Piston ring of

3rd, 4th, 5th gears; 21-Sliding sleeve of 5th shift synchronizer; 22-Synchronizer gear ring for 3rd, 4th, 5th gears; 23-Connecting gear

for 5th gear; 24-rear shaft snap ring of countershaft; 25-Reverse gear idler component; 26-Reverse gear idler shaft; 27-Platen of

reverse gear idler shaft; 28-Intermiedate connecting plate; 29-Rear bearing cap of output shaft; 30-Hexagonal screw.

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Figure 10-2-4 Intermediate Connecting Plate Component of Transmission-2

1-Screw plug of fixing spring; 2-Fork shaft fixing spring for 1st, 2nd, 3rd, 4th and reverse gears; 3-Steel ball 9.252; 4-shifting

fork lock screw for 1st and 2nd gear; 5-shifting fork for 1st and 2nd gear; 6-Shifting shaft for 1st and 2nd gears; 7-spring column pin;

8-Shifting guide block for 1st and 2nd gear; 9-Short interlock pin; 10-Interlock guide column; 11-Shifting fork shaft for 3rd and 4th

gear; 12- snap ring; 13-Shifting fork for 3th and 4th gear; 14-Shifting lever for reverse gear; 15-Rocker arm bracket for reverse gear;

16-Shifting block for reverse gear; 17-Reverse gear rocker arm; 18- snap ring; 19-Interlock pin; 20-Shifting fork shaft for reverse

gear; 21-Shifting guide block for 5

th

/reverse gear; 22-Shifting fork shaft for 5th gear; 23-Fork shaft fixing spring for 5th gear;

24-Shifting fork for 5th gear.

Chapter 10 Chassis Structure and Service

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Figure 10-2-5 Output Shaft of Transmission

1-Gear hub shaft snap ring for 3rd and 4th gears; 2-Synchronizer spring piston ring for 3rd, 4th and 5th gears; 3-Synchronizer

gear hub for 3rd and 4th gears; 4-Synchronizer inserts for 3rd and 4th gears; 5-Synchronizer sliding sleeve for 3rd and 4th gears;

6-Synchronizer gear ring for 3rd, 4th and 5th gears; 7-Gear component of 3rd gear; 8-Needle bearing of 3rd gear; 9-Steel ball;

10-Output shaft; 11-Synchronizer inserts of 2nd gear; 12-Needle bearing of 2nd gear; 13-Gear component of 2nd gear;

14-Synchronizer gear ring for 1st and 2nd gears; 15-Synchronizer spring piston ring for 1st and 2nd gears; 16-Synchronizer gear hub

for 1st and 2nd gears; 17-Synchronizer sliding sleeve for 1st and 2nd gears; 18-Gear component of 1st gear; 19-Needle bearing of 1st

gear; 20-Gear shaft bush of 1st gear; 21-Rear bearing of output shaft; 22-Rear bearing thrust ring of output shaft; 23-Gear of 5th gear;

24-Gear shaft snap ring for 5th gear; 25-Driving gear snap ring of odometer; 26-Driving gear of odometer.