Engine JAC HFC4DA1-2C. Service manual — part 124
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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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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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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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Transmission
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Transmission
-19-
Removal/Installation
Removal/Installation
Removal/Installation
Removal/Installation
Manual
Manual
Manual
Manual transmission
transmission
transmission
transmission
1.
Remove manual transmission.
●
Oil drainage
Attention:
Remove oil drain plug with
wrench and drain oil through this plug instead
of other parts.
2.
Remove release bearing from input shaft front cap.
3.
Remove input shaft front cap from transmission.
4.
Remove clutch housing.
Attention: If the transmission housing is assembled
tightly with clutch housing, a rubber hammer or
copper rod can be applied to knock on the housing
edge to make them become loose.
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