Engine JAC HFC4DA1-2C. Service manual — part 131
MT
MT
MT
MT Manual
Manual
Manual
Manual 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
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
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
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