JAC HFC4DA1-2C engine. Instruction — part 33
MT
MT
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MT Instruction
Instruction
Instruction
Instruction Transmission
Transmission
Transmission
Transmission
-35-
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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MT Instruction
Instruction
Instruction
Instruction Transmission
Transmission
Transmission
Transmission
-36-
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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MT
MT Instruction
Instruction
Instruction
Instruction Transmission
Transmission
Transmission
Transmission
-37-
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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MT Instruction
Instruction
Instruction
Instruction Transmission
Transmission
Transmission
Transmission
-38-
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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MT Instruction
Instruction
Instruction
Instruction Transmission
Transmission
Transmission
Transmission
-39-
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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MT Instruction
Instruction
Instruction
Instruction Transmission
Transmission
Transmission
Transmission
-40-
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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MT Instruction
Instruction
Instruction
Instruction Transmission
Transmission
Transmission
Transmission
-41-
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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Instruction
Instruction
Instruction Transmission
Transmission
Transmission
Transmission
-42-
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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MT Instruction
Instruction
Instruction
Instruction Transmission
Transmission
Transmission
Transmission
-43-
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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MT
MT Instruction
Instruction
Instruction
Instruction Transmission
Transmission
Transmission
Transmission
-44-
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
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
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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
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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
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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
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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
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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.
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