Engine JAC HFC4DA1-2C. Manual — part 120
Chassis
Chassis
Chassis
Chassis Volume
Volume
Volume
Volume Contents
Contents
Contents
Contents
- 3 -
Steering
Steering
Steering
Steering System
System
System
System
Steering System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Explosive View of Steering System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Introduction of Steering System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Diagnosis and Testing
Steering System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Operating Principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Inspection and confirmation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 156
Fault Symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..159
Removal and Installation
Removal and Installation of Steering System. . . . . . . . . . . . . . . . . . . . . . . . . . 164
Removal and Installation of steering wheel. . . . . . . . . . . . . . . . . . . . . . . . . . ... 167
Wheels
Wheels
Wheels
Wheels and
and
and
and Tires
Tires
Tires
Tires
Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..174
Explosive View of Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 175
Precaution for Tire Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 175
Diagnosis and Testing
Removal/Installation Instruction of Tire Assembly. . . . . . . . . . . . . . . . . . . . . . . . 176
Fault Symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..177
Removal/installation
Removal/installation of wheel
and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . 178
Four-Wheel
Four-Wheel
Four-Wheel
Four-Wheel Alignment
Alignment
Alignment
Alignment
Four-Wheel Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
Preparation before four-wheel alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . ... 184
Diagnosis and Testing
Four-Wheel Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Function of each angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Common fault symptom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Adjustment
Four/wheel alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 187
Attached
Attached
Attached
Attached List
List
List
List—
—
—
—SUNRAY
SUNRAY
SUNRAY
SUNRAY Special
Special
Special
Special Service
Service
Service
Service Tools
Tools
Tools
Tools
CL
CL
CL
CL Clutch
Clutch
Clutch
Clutch
- 1-
Clutch
Clutch
Clutch
Clutch
Applied models: SUNRAY products manufactured by JAC
Subject
Page
Instruction
Instruction
Instruction
Instruction and
and
and
and Operation
Operation
Operation
Operation
Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1
Explosive View of Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 1
Introduction of Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Diagnosis
Diagnosis
Diagnosis
Diagnosis and
and
and
and Testing
Testing
Testing
Testing
Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2
Operating Principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 3
Fault Symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4
Removal
Removal
Removal
Removal and
and
and
and Installation
Installation
Installation
Installation
Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
Specification
Specification
Specification
Specification
Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14
Tightening Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
CL
CL
CL
CL Clutch
Clutch
Clutch
Clutch
- 2-
Instruction
Instruction
Instruction
Instruction and
and
and
and Operation
Operation
Operation
Operation
Clutch
Clutch
Clutch
Clutch
System diagram:
Diagram of Clutch Control System
1.Clutch
2.Clutch release cylinder
3.Release fork
4.Release bearing
5.Clutch line
6.Clutch master cylinder 7.Clutch pedal
8.Fluid reservoir
Schematic Diagram of Clutch Control Principle
1.Clutch pedal
2.Clutch master cylinder
3.Clutch hydraulic line
4.Clutch release cylinder
5.Release fork
6.Pressure plate
7.Driven disc
8.Flywheel
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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