JAC HFC4DA1-2C engine. Instruction — part 31
CL
CL
CL
CL Clutch
Clutch
Clutch
Clutch
- 3-
Instruction
Instruction
Instruction
Instruction and
and
and
and Operation
Operation
Operation
Operation
Operating
Operating
Operating
Operating Principle
Principle
Principle
Principle
The clutch control is realized via remote hydraulic
control of clutch engagement and release for the power
transmission and cutting-off. Specific implementations
are as follows:
In clutch release: The driver steps on the clutch pedal 1
and push the special clutch hydraulic fluid stored in the
master cylinder via the push rod connecting the pedal
and the clutch master cylinder 2 to flow through the line
3 consisting of pipes and hoses and enter the release
cylinder 4. The release fork 5 pushes the release bearing
shaft forward and then pushes the diaphragm spring of
clutch pressure plates 6 separated. Then, the chamber
clearance between the driven disc 7 and flywheel 8
becomes larger. Because of the decreased friction force,
the driven disc 7 can not transmit power to the input
shaft of the transmission, the power is cut off.
In clutch engagement: The driver releases the clutch
pedal slowly, the pressure applied on the diaphragm
spring separated finger of clutch pressure plates 6
decreases and the spring
returns gradually. With
relevant level effect, the fluid chamber of the slave
cylinder becomes smaller while the fluid chamber of the
master cylinder becomes larger and the clutch pedal is
lifted slowly; At the same time, the distance between the
pressure plate 6 and flywheel becomes smaller that the
chamber clearance among the driven disc 7, flywheel 8
and pressure plate 6 becomes smaller. Because of the
increased friction force, the driven disc 7 starts power
transmission to the input shaft of the transmission, the
power is engaged.
Inspection
Inspection
Inspection
Inspection and
and
and
and Maintenance
Maintenance
Maintenance
Maintenance
Clutch:
1.
Clutch pressure plate
①
Inspect the end of the diaphragm spring for wears
and altitude difference. In the case of obvious
wears and altitude difference out of the limit value,
replace the clutch pressure plate.
Limit value:0.5mm
②
Inspect the surface of the pressure plate for wears,
cracks and discoloration.
③
Inspect rivets of the pressure plate for looseness. In
the case of loose rivets, replace the clutch pressure
plate.
2.
Clutch driven disc
Attention:
It is not allowed to clean the clutch driven disc with
petrol!
①
Inspect its surface for loose rivets, signal side
contact, degradation due to burns and adherent
grease. In the case of such problems, replace the
clutch driven disc.
②
Measure the rivet settlement. In the case of
settlement out of the limit value, replace the clutch
driven disc.
Limit value: 0.3mm
③
Inspect the torsion spring for looseness, breakage.
In the case of such problems, replace the clutch
driven disc.
④
Install the clutch driven disc onto the input shaft,
inspect it for its sliding condition and rotation
direction for looseness. In the case of poor sliding,
clean and reinspect it after installation. In the case
of obvious looseness, replace the clutch driven disc
or input shaft or replace both simultaneously.
3.
Clutch release bearing
Attention:
Inspect the bearing for burns, damages, abnormal noise,
and unsmooth rotation.
Inspect the release bearing and diaphragm spring or
inspect the contact surface of the release fork for
abnormal wears. In case of such problems, carry out
replacement.
4.
Release fork
In the case of abnormal wears between the release fork
and the contact surface with the bearing, carry out
replacement.
Clutch release cylinder:
Release cylinder:
1.
Inspect the inner surface of the release cylinder for
rusting and damages.
2.
Measure the inner diameter of the release cylinder
with
a cylinder gauge
at three places
(bottom,
intermediate part and upper part). In the case of the
clearance with the piston outer circumference out of the
limit value, replace the release cylinder assembly.
Limit value: 0.15mm
Clutch hydraulic fluid
Attention:
Do not carry out operations to this system with a
vacuum pump or any other evacuation power devices.
Inspect the fluid level of the clutch hydraulic fluid,
please ensure the normal fluid level.
Air bleeding of the line:
Attention:
After the removal of clutch line, clutch master cylinder,
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CL
CL
CL
CL Clutch
Clutch
Clutch
Clutch
- 4-
clutch slave cylinder and hydraulic release bearing or in
the case of spongy clutch pedal, carry out air bleeding
for the system.
1.
Loosen bleed bolts of the clutch release cylinder.
2.
Step on the clutch pedal slowly until complete air
bleeding has been done.
3.
Step on the pedal completely, maintain the status
and tighten the bleed bolts.
4.
Refill with hydraulic fluid for the clutch hydraulic
system.
Attention:
Attention:
Attention:
Attention:
Keep the fluid level in the fluid reservoir between
MIN and MAX marks all the time.
5.
Repeat the abovementioned steps until there is
clear clutch hydraulic fluid draining out without
any bubbles.
6.
Confirm normal operation of the clutch.
①
Start the engine, step on the clutch pedal and shift
into the reverse gear after 2 seconds. In the case of
large noise during gear selection, step the clutch
pedal to the floor for 5 times in order to carry out
system air bleeding.
②
Wait for 30 seconds and reinspect the clutch
operation. In the case of remained large noise,
repeat air bleeding.
Fault diagnosis
Performance diagnosis for the clutch assembly and
clutch control system should be carried out by
experienced vehicle maintenance technicians.
After proper diagnosis, carry out adjustment or part
replacement according to corresponding troubleshooting
and proper steps of specific procedures in the service
instruction. For all parts to be replaced, only authorized
parts of JAC shall be applied. For damaged clutch
pressure plates or driven discs, they are not repairable
and it is necessary to replace corresponding assemblies.
Numbers in the diagnosis table have no relations with
the inspection sequence. There is no precedence
relationship for various possible causes.
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CL
CL
CL
CL Clutch
Clutch
Clutch
Clutch
- 5-
Common
Common
Common
Common ffffault
ault
ault
ault diagnosis
diagnosis
diagnosis
diagnosis table
table
table
table
Fault Symptom
Possible Cause of Fault
Troubleshooting
Incapable
release
Incapable release of the clutch means unable functioning of the clutch
and the power transmitted from the engine can not be cut off.
Inspect for following conditions:
1. Deformation in clutch release lever
2. Deformation in diaphragm spring
3. Punsture in diaphragm spring support ring
4. Improper adjustment of clutch pedal control system
5. Seizure of clutch friction lining with flywheel or clutch pressure
plate
Replace deformed, worn and fractured
parts. Adjust clutch pedal control system.
Incomplete
release
Incomplete clutch release may lead to incapable cutting-off of power
transmitted from the engine and the shift lever will be hard to operate
due to continuous rotation of clutch friction linings and transmission
input shaft.
Inspect for following conditions:
1. Deformation in clutch friction lining. In the rotation of the lining,
there will be swing.
2. Damage in clutch friction lining
3. Mismatching of clutch friction lining spline and transmission input
shaft or damage in spline tooth surface
4. Seizure of clutch friction lining with flywheel or clutch pressure
plate
5. Thickness of flywheel/clutch pressure plate/ clutch friction lining
out of specified dimension
6. Mechanical failure or improper adjustment in clutch pedal control
system
Replace deformed, worn and fractured parts
or parts out of specified dimension. In the
case of poor matching of clutch friction
lining with the operation of transmission
input shaft spline, replace the clutch friction
lining and if necessary, replace transmission
input shaft.
In the case of damaged clutch friction
lining or clutch friction lining out of
specified dimension, replace it.
Replace inapplicable clutch thrust bearing.
Adjust clutch system, remove unnecessary
clearances
and
eliminate
mechanical
failures.
Reinstall improperly-assembled parts.
Incomplete
engagement
Incomplete
clutch
engagement
may
lead
to
incapable
power
transmission of the engine to the transmission input shaft and clutch
friction linings will slip.
Inspect for following conditions:
1.
Smudginess in clutch friction lining due to engine oil or grease
2. Damage in clutch friction lining
3. No free travel for clutch pedal
4. Deformation or damage in diaphragm spring/clutch pressure plate
/clutch release lever/clutch friction lining spline
5. Mechanical failure or improper adjustment in clutch pedal control
system
Replace deformed, worn and fractured
parts.
Replace clutch friction linings or faulted
clutch assembly.
Carry out proper adjustment of clutch pedal
free travel.
Adjust clutch system, remove unnecessary
clearances
and
eliminate
mechanical
failures.
Reinstall improperly-assembled parts.
Slipping
Clutch friction lining slipping may lead to incapable normal power
transmission of the engine.
Inspect for following conditions:
1. Wear in clutch friction lining.
2. Smudginess in clutch friction lining due to engine oil or grease
3. Incomplete clutch engagement
4. Thickness of flywheel/clutch pressure plate/ clutch friction lining
out of specified dimension, friction surface out of specified
specification
5. Overhigh temperature of clutch housing due to improper driving
6. Installation of improper clutch
Replace deformed, worn and fractured parts
or parts out of specified dimension and
specification.
Carry out the same troubleshooting with
“Incomplete
release”
and
“Incomplete
engagement”
Turn off the engine, cool the clutch housing
(in the case of overhigh temperature in the
housing)and carry out further diagnosis.
Carry out correct installation for specified
clutch.
Adjust clutch system, remove unnecessary
clearances
and
eliminate
mechanical
failures.
Reinstall improperly-assembled parts.
It is not allowed for the driver to step on the
clutch pedal all the time.
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CL
CL
CL
CL Clutch
Clutch
Clutch
Clutch
- 6-
Fault Symptom
Possible Cause of Fault
Troubleshooting
Noise
Inspect for following conditions:
1. Improper clutch friction lining.
2. Poor balance
3. Fault in clutch thrust bearing
4. Damage in torsion damping spring of clutch friction lining
Replace deformed, worn and fractured
parts.
Install specified clutch friction lining.
In the case of poor balance in some parts,
replace clutch assembly.
Adjust clutch pedal control system.
Reinstall improperly-assembled parts.
Shudder
There may be clutch shudder in the case of incapable smooth
engagement of the clutch friction lining with the flywheel.
Inspect for following conditions:
1. Clutch friction lining damping spring out of specified specification
2. Clutch friction lining out of specified specification
3. Smudginess in clutch friction lining due to engine oil or grease
Replace clutch assembly.
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CL
CL
CL
CL Clutch
Clutch
Clutch
Clutch
- 7-
Removal
Removal
Removal
Removal and
and
and
and Installation
Installation
Installation
Installation
Clutch
Clutch
Clutch
Clutch
1.
Disconnect the negative cable of battery.
2.
Lift the vehicle.
3.
Remove the clutch slave cylinder.
�
Remove bleed bolts of clutch slave cylinder
and drain system brake fluid completely.
�
Remove the clutch slave cylinder
4.
Remove the shift cable assembly.
Attention:
Remove the shift cable and fixit on one side.
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CL
CL
CL
CL Clutch
Clutch
Clutch
Clutch
- 8-
Removal
Removal
Removal
Removal and
and
and
and Installation
Installation
Installation
Installation (continued)
(continued)
(continued)
(continued)
Clutch
Clutch
Clutch
Clutch
5.
Remove the rear support pad of the transmission.
Jack up the transmission with a jack.
6.
Remove bolts at the side of connection between the
transmission rear flange plate and the propeller
shaft.
7.
Remove the starter and the bolts at the side of
connection between the transmission and generator.
Move the removed transmission backward.
8.
Insert special tools in the center of pressure plate.
�
Remove mounting bolts of the pressure plate
assembly and pay attention to the installation
position.
Attention:
In the processing of removal, there should be one
holding up the pressure plate assembly to avoid
pricks to people.
9.
Remove pressure plates and friction linings and
place them horizontally on the ground. Do not
smudge them and it is not allowed to wipe the
pressure plates and friction linings with oily cloth.
10. Remove mounting bolts of the flywheel. Pay
attention to the removal process of the flywheel
and it is not allowed to fix the gear ring or
crankshaft position sensor target wheel with a
screwdriver.
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CL
CL
CL
CL Clutch
Clutch
Clutch
Clutch
- 9-
Removal
Removal
Removal
Removal and
and
and
and Installation
Installation
Installation
Installation (continued)
(continued)
(continued)
(continued)
Clutch
Clutch
Clutch
Clutch
11. Remove the release bearing. Attention: Do not
make the lubricating grease to contact with the
clutch assembly.
12. Remove the release fork.
�
Remove the dust boot at the outside of the
release fork.
�
Snap the release fork. Attention: the release
fork is clipped on the support pin and pay
attention to the spring force to avoid injury in
hands.
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CL
CL
CL
CL Clutch
Clutch
Clutch
Clutch
- 10-
Removal
Removal
Removal
Removal and
and
and
and Installation
Installation
Installation
Installation (continued)
(continued)
(continued)
(continued)
Installation
Installation
Installation
Installation of
of
of
of Clutch
Clutch
Clutch
Clutch
Installation:
1.
Install the flywheel onto the crankshaft and pay
attention to the fixed pin there.
Attention:
Attention:
Attention:
Attention:
There should be another man for cooperation in the
installation and pay attention to safety.
2.
Insert the special tool into the saddle bore of guide
bearing at the rear end of crankshaft. Set the new
friction lining and pressure plate into the special
tool. Install the pressure plate assembly in place. In
the process of bolt tightening, pay attention to
tighten the bolts one by one diagonally. Pull out the
special tool at last.
3.
Install the release lever into the clutch housing and
clamp the release lever. Finally, install a dust boot
in the rear of the installed release lever.
4.
Apply a layer of lubricating grease on the inner
side of the release bearing and install the release
bearing into the transmission input shaft.
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CL
CL
CL
CL Clutch
Clutch
Clutch
Clutch
- 11-
Removal
Removal
Removal
Removal and
and
and
and Installation
Installation
Installation
Installation (continued)
(continued)
(continued)
(continued)
Installation
Installation
Installation
Installation of
of
of
of Clutch
Clutch
Clutch
Clutch
5.
Install the transmission in the clamping jaw to
corresponding position and install a bolt there
without tightening.
6.
Turn the transmission and install the transmission
input shaft into the center of the installed clutch
assembly.
7.
Shake the transmission to inspect whether the
transmission input shaft is installed in place. Install
and
tighten
connecting
bolts
between
the
transmission and engine with attention to the
tightening torque. Install the starter into the
transmission assembly.
8.
Install the mount pad in the rear of transmission
and tighten it. Install the propeller shaft to the
flange plate of the transmission output shaft with
attention to the installation position.
9.
Install the transmission gear shift mechanism cable
in place. Pay attention to the cotter pin involved in
the installation process and replace the used cotter
pin with a new one.
10. Clamp the moving side of the removed clutch slave
cylinder into the release lever and fix the slave
cylinder with bolts.
11.
After installation of the slave cylinder, lower the
vehicle and carry out air bleeding for the clutch
hydraulic system.
12. Connect the negative cable of battery.
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CL
CL
CL
CL Clutch
Clutch
Clutch
Clutch
- 12-
Removal
Removal
Removal
Removal and
and
and
and Installation
Installation
Installation
Installation (continued)
(continued)
(continued)
(continued)
Clutch
Clutch
Clutch
Clutch master
master
master
master cylinder
cylinder
cylinder
cylinder
1.
Disconnect the negative cable of battery.
2.
Remove the lower protective plate of driver’s
instrument panel.
Attention:
Attention:
Attention:
Attention:
Pay attention not to damage the instrument clip
during its removal.
3.
Drain brake fluid in the brake fluid reservoir.
4.
Remove three mounting bolts of the clutch master
cylinder and do not take down the cylinder after
bolt removal.
5.
Remove output and input oil pipes of the clutch
master cylinder.
6.
Remove the cotter pin of the clutch master cylinder
and pull out the cotter pin.
7.
Disconnect the clutch switch plug.
8.
Remove the clutch switch with an open end wrench
with attention of installation position.
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CL
CL
CL
CL Clutch
Clutch
Clutch
Clutch
- 13-
Removal
Removal
Removal
Removal and
and
and
and Installation
Installation
Installation
Installation ((((
continued
continued
continued
continued
))))
Clutch
Clutch
Clutch
Clutch master
master
master
master cylinder
cylinder
cylinder
cylinder
Installation
1.
Clean the clutch master cylinder completely.
2.
In the installation of output and input hoses of the
master cylinder, confirm that they are well
tightened.
3.
Inspect the master cylinder oil pipe for deformation
or crush.
4.
Align the master cylinder to screw holes and carry
out tightening according to standard torque.
5.
Insert the fixed pin of the master cylinder and fix it
with a new cotter pin.
6.
Screw the clutch switch into pedal position and
inspect for its proper installation position with a
multimeter.
7.
Install the lower protective plate on the driver’s
instrument panel.
8.
Connect the negative cable of battery.
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CL
CL
CL
CL Clutch
Clutch
Clutch
Clutch
- 14-
Specification
Specification
Specification
Specification
Tightening
Tightening
Tightening
Tightening Torque
Torque
Torque
Torque
Part name
Tightening torque Nm
Quantity
Clutch master cylinder bolt and nut cap
23~29
3
Nut for installing the master cylinder to the vehicle body
23~29
4
Clutch slave cylinder bolt
120~140
3
Clutch hose support bolt
23~29
1
Clutch air bleeder pipe bolt
23~29
1
Clutch hose punching bolt
45~50
1
Air bleeder outlet oil pipe joint
23~29
1
Pressure plate mounting bolt
45~50
6
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MT
MT
MT
MT Manual
Manual
Manual
Manual Transmission
Transmission
Transmission
Transmission
-15-
Manual
Manual
Manual
Manual Transmission
Transmission
Transmission
Transmission
Applied models: SUNRAY products manufactured by JAC
Subject
Page
Instruction
Instruction
Instruction
Instruction and
and
and
and Operation
Operation
Operation
Operation
Manual Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Explosive View of Manual Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Introduction of Manual Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...16
Diagnosis
Diagnosis
Diagnosis
Diagnosis and
and
and
and Testing
Testing
Testing
Testing
Manual transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17
Inspection and confirmation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fault Symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal/Installation
Removal/Installation
Removal/Installation
Removal/Installation
Manual Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Specifications
Specifications
Specifications
Specifications
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Tightening Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Care and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 44
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MT
MT
MT
MT Manual
Manual
Manual
Manual Transmission
Transmission
Transmission
Transmission
-16-
Instruction
Instruction
Instruction
Instruction and
and
and
and Operation
Operation
Operation
Operation
SUNRAY vehicles adopt synchronizer manual-shift mechanical transmissions of good shifting flexibility, good hand
feel, low noise, compact structure, large carrying capacity as well as good sealing performance, which consist of five
forward gears and one reverse gear. All gears are of helical teeth. Except for the reverse gear that adopts direct
transmission through sleeve, the other gears adopt
three-cone (single cone, three-cone only for 1
st
/2
nd
gear)
synchronizer
. Shifting mechanism is of cable-type remote control.
Principles of motion:
1
st
gear
Engine→Clutch→Input shaft 1→Main gear of countershaft 15→Countershaft 11→
1
st
driving gear
6→1st/2nd gear
synchronizer 5→Output shaft 10
2
nd
gear
Engine→Clutch→Input shaft 1→Main gear of countershaft 15→Countershaft 11→2
nd
driving gear
4→1st/2nd gear
synchronizer 5→Output shaft 10
3
rd
gear
Engine→Clutch→Input shaft 1→Main gear of countershaft 15→Countershaft 11→3
rd
gear of countershaft 14→3
rd
driving gear
3→3rd/4th gear synchronizer2→Output shaft 10
4
th
gear
Engine→Clutch→Input shaft 1→3rd/4th gear synchronizer 2→Output shaft 10
5
th
gear
Engine→Clutch→Input shaft 1→Main gear of countershaft 15→Countershaft 11→5
th
gear of countershaft 12→5
th
driving gear 9→5th/reverse gear synchronizer 8→Output shaft 10
Reverse gear
Engine→Clutch→Input shaft 1→Main gear of countershaft 15→Countershaft 11→Reverse gear 13→Reverse driving
gear 7→5th/reverse gear synchronizer 8→Output shaft 10
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MT
MT
MT
MT Manual
Manual
Manual
Manual Transmission
Transmission
Transmission
Transmission
-17-
Instruction
Instruction
Instruction
Instruction and
and
and
and Operation
Operation
Operation
Operation
Control
Control
Control
Control
Gear selector lever and gear shift lever can be controlled
through controlling the control handle inside cab to
realize gear shifting. Different directions shown on the
control handle grip corresponds to different gear select
and shift positions. The control handle shall return to
neutral position automatically after each time of gear
removal. Gear selection can only be performed after the
control handle is returned to the neutral position.
1.
In order to shift gear, depress the clutch pedal fully
to make the transmission out of engine torque and
then control the gear shift lever quickly to shift
gear. Please adopt low speed gear when starting.
2.
Please adopt low speed gear during vehicle
climbing, running downhill or turning. Don’t let
the vehicle idling with clutch released.
3.
In case it is difficult to control the control handle,
please stop and inspect. Don’t apply it violently.
Kilometers
Kilometers
Kilometers
Kilometers applicable
applicable
applicable
applicable to
to
to
to each
each
each
each forward
forward
forward
forward gear
gear
gear
gear of
of
of
of
transmission:
transmission:
transmission:
transmission:
Gear
Position
1
st
gear
2
nd
gear
3
rd
gear
4
th
gear
5
th
gear
Kilometers
0~15
20~30
35~45
50~60
65~75
Attention:
Attention:
Attention:
Attention:
1.
1.
1.
1.
Gear
Gear
Gear
Gear
shifting
shifting
shifting
shifting
of
of
of
of
transmission
transmission
transmission
transmission
should
should
should
should
be
be
be
be
performed
performed
performed
performed within
within
within
within relevant
relevant
relevant
relevant kilometer
kilometer
kilometer
kilometer range.
range.
range.
range.
2.
2.
2.
2.
The
The
The
The applicable
applicable
applicable
applicable kilometers
kilometers
kilometers
kilometers may
may
may
may vary
vary
vary
vary when
when
when
when the
the
the
the
transmission
transmission
transmission
transmission is
is
is
is equipped
equipped
equipped
equipped to
to
to
to different
different
different
different vehicles.
vehicles.
vehicles.
vehicles.
Principle
Principle
Principle
Principle of
of
of
of gear
gear
gear
gear shifting
shifting
shifting
shifting
Under the forward running status, the requirements of
gear shifting is as follows: gear shifting from 1
st
gear to
5
th
gear step by step for speeding up, gear shifting from
5
th
gear to 1
st
gear step by step for speeding down;
reverse gear can be shifted to in 3 seconds of pause after
the clutch pedal is depressed under motionless state of
vehicle; don’t apply reverse gear under running state
and don’t apply forward gears under reversing state.
Don’t use the control handle of transmission as an
armrest, in order to avoid early wear of shift fork.
Attention:
Attention:
Attention:
Attention: In
In
In
In case
case
case
case of
of
of
of any
any
any
any emergency
emergency
emergency
emergency occurs
occurs
occurs
occurs during
during
during
during
running
running
running
running state,
state,
state,
state, you
you
you
you may
may
may
may perform
perform
perform
perform gear
gear
gear
gear shifting
shifting
shifting
shifting
without
without
without
without following
following
following
following this
this
this
this principle
principle
principle
principle.
Meaning
Meaning
Meaning
Meaning of
of
of
of transmission
transmission
transmission
transmission name:
name:
name:
name:
Inspection
Inspection
Inspection
Inspection and
and
and
and Confirmation
Confirmation
Confirmation
Confirmation
1.
Check input shaft assembly
1)
Check input shaft for gear teeth fracture, pitting,
severe wear or scuffing of tooth surface. If any,
please replace the input shaft.
2)
Check input shaft spline for any severe wear or
damage. If any, please replace the input shaft.
3)
Rotate bearing by hand to check for non-flexible
rotation or sticking. If any, please replace the
bearing.
Note:
Note:
Note:
Note:
Please check the stop ring on bearing during
replacement of bearing. If it is deformed, please
replace it.
2.
Check output shaft assembly
Check input shaft for gear teeth fracture, pitting,
severe wear or scuffing of tooth surface. If any,
please replace the output shaft.
Note:
Note:
Note:
Note:
Rotate bearing by hand to check for non-flexible
rotation or sticking. If any, please replace the
bearing.
3.
Check synchronizer ring
1)
Check tooth surface of synchronizer ring for any
damage.
2)
Check conical surface for any damage or wear;
check if the screw is crushed.
3)
When the synchronizer ring is pressed close to gear,
check clearance “A”. If “A” is below the limit,
please replace the ring.
Limit
Limit
Limit
Limit value:
value:
value:
value: 0.5mm
0.5mm
0.5mm
0.5mm
4.
Check synchronizer gear sleeve and gear hub
1)
Assemble the synchronizer gear sleeve and gear
hub together and check for smooth sliding but no
sticking.
2)
Check front and read end of inner surface of gear
sleeve for any damage.
Attention: In case the synchronizer gear sleeve or gear
hub is in need of replacement, they should be replaced
as a whole.
Torque 280N.M (actual torque up to 300N.M)
Synchronizer structure
Five forward gears
Six gears
Synchronizer ring
Gear
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MT
MT
MT
MT Manual
Manual
Manual
Manual Transmission
Transmission
Transmission
Transmission
-18-
Instruction
Instruction
Instruction
Instruction and
and
and
and Operation
Operation
Operation
Operation
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
Jumping
back
to
neutral
position under running state
Excessive wear of shift fork shaft arc,
elastic deformation of lock ball spring
Check if the operating system has pushed the gear
shift rocker arm of transmission into place; or with
the transmission removed, push the shift fork into
gear by hand to check gear meshing status.
Excessive wear of shift fork working face
In case of incomplete meshing, please check shift
fork for deformation or working face excessive wear.
Excessive wear of joint surface of shift fork
gear ring or gear sleeve
In case of complete meshing, please check wear
condition of inverted cone of gear sleeve and
engaged gear.
Axial looseness of gear
If excessive clearance is felt, please check fork shaft
groove and guide spring for any wear or failure.
Difficulty in gear shifting, loud
impact sound in gear shifting,
or
difficulty
in
shifting
to
certain
gear
with
normal
operation of clutch
Severe wear of synchronizer ring
Replace synchronizer ring.
Noise generated in transmission
1. Regular impact sound
2. Uniform noise
Caused by breakage of individual gear
tooth
Check relevant part and remove it.
Backlash increase or gear damage
Remove, check and clean or replace damaged gear.
Bearing wear
Remove, check and clean or replace damaged
bearing.
Insufficient lube oil
Change oil or add new oil.
Oil leak
Adding too much oil, too high oil level
Remove oil filler plug to check oil level.
Excessive wear or damage of oil seal
Replace oil seal.
Uneven application of sealant or damage of
sealing paper pad
Remove parts relevant to each joint surface and
apply sealant evenly, or replace paper pad.
Failure of vent plug
Replace vent plug.
Joint surface bump not shaved in time
Remove parts relevant to each joint surface to have
the bump point shaved.
Abnormal spoilage of bearing
Too dirty lube oil
Change oil.
Inadequate lubrication or nonconforming or
inferior
lube oil
Check oil level, add or change oil.
Unqualified bearing adopted
Replace bearing.
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