JAC HFC4DA1-2C engine. Service Manual — part 31

CL Clutch

Clutch

- 3-

Instruction

Instruction and

and

and Operation

Operation

Operating

Operating 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 and

and

and 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.

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.

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 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.

Step on the clutch pedal slowly until complete air
bleeding has been done.

Step on the pedal completely, maintain the status
and tighten the bleed bolts.

Refill with hydraulic fluid for the clutch hydraulic
system.
Attention:

Attention:

Keep the fluid level in the fluid reservoir between
MIN and MAX marks all the time.

Repeat the abovementioned steps until there is
clear clutch hydraulic fluid draining out without
any bubbles.

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
manual. 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 Clutch

Clutch

- 5-

Common

Common ffffault

ault

ault diagnosis

diagnosis

diagnosis 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

incapable

power

transmission of the engine to the transmission input shaft and clutch
friction linings will slip.

Inspect for following conditions:

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 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 Clutch

Clutch

- 7-

Removal

Removal and

and

and Installation

Installation

Clutch

Disconnect the negative cable of battery.

Lift the vehicle.

Remove the clutch slave cylinder.

�

Remove bleed bolts of clutch slave cylinder
and drain system brake fluid completely.

�

Remove the clutch slave cylinder

Remove the shift cable assembly.

Attention:

Remove the shift cable and fixit on one side.

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CL Clutch

Clutch

- 8-

Removal

Removal and

and

and Installation

Installation

Installation (continued)

(continued)

Clutch

Remove the rear support pad of the transmission.
Jack up the transmission with a jack.

Remove bolts at the side of connection between the
transmission rear flange plate and the propeller
shaft.

Remove the starter and the bolts at the side of
connection between the transmission and generator.
Move the removed transmission backward.

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.

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 Clutch

Clutch

- 9-

Removal

Removal and

and

and Installation

Installation

Installation (continued)

(continued)

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 Clutch

Clutch

- 10-

Removal

Removal and

and

and Installation

Installation

Installation (continued)

(continued)

Installation

Installation of

of Clutch

Clutch

Installation:

Install the flywheel onto the crankshaft and pay
attention to the fixed pin there.

Attention:

There should be another man for cooperation in the
installation and pay attention to safety.

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.

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.

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 Clutch

Clutch

- 11-

Removal

Removal and

and

and Installation

Installation

Installation (continued)

(continued)

Installation

Installation of

of Clutch

Clutch

Install the transmission in the clamping jaw to

corresponding position and install a bolt there
without tightening.

Turn the transmission and install the transmission
input shaft into the center of the installed clutch
assembly.

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.

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.

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 Clutch

Clutch

- 12-

Removal

Removal and

and

and Installation

Installation

Installation (continued)

(continued)

Clutch

Clutch master

master

master cylinder

cylinder

Disconnect the negative cable of battery.

Remove the lower protective plate of driver’s
instrument panel.

Attention:

Pay attention not to damage the instrument clip
during its removal.

Drain brake fluid in the brake fluid reservoir.

Remove three mounting bolts of the clutch master
cylinder and do not take down the cylinder after
bolt removal.

Remove output and input oil pipes of the clutch
master cylinder.

Remove the cotter pin of the clutch master cylinder
and pull out the cotter pin.

Disconnect the clutch switch plug.

Remove the clutch switch with an open end wrench
with attention of installation position.

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CL Clutch

Clutch

- 13-

Removal

Removal and

and

and Installation

Installation

Installation ((((

continued

))))

Clutch

Clutch master

master

master cylinder

cylinder

Installation
1.

Clean the clutch master cylinder completely.

In the installation of output and input hoses of the
master cylinder, confirm that they are well
tightened.

Inspect the master cylinder oil pipe for deformation
or crush.

Align the master cylinder to screw holes and carry
out tightening according to standard torque.

Insert the fixed pin of the master cylinder and fix it
with a new cotter pin.

Screw the clutch switch into pedal position and
inspect for its proper installation position with a
multimeter.

Install the lower protective plate on the driver’s
instrument panel.

Connect the negative cable of battery.

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CL Clutch

Clutch

- 14-

Specification

Tightening

Tightening Torque

Torque

Part name

Tightening torque Nm

Quantity

Clutch master cylinder bolt and nut cap

23～29

Nut for installing the master cylinder to the vehicle body

23～29

Clutch slave cylinder bolt

120～140

Clutch hose support bolt

23～29

Clutch air bleeder pipe bolt

23～29

Clutch hose punching bolt

45～50

Air bleeder outlet oil pipe joint

23～29

Pressure plate mounting bolt

45～50

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MT Manual

Manual

Manual Transmission

Transmission

-15-

Manual

Manual Transmission

Transmission

Applied models: SUNRAY products manufactured by JAC

Subject

Page

Instruction

Instruction and

and

and Operation

Operation

Manual Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Explosive View of Manual Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Introduction of Manual Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...16

Diagnosis

Diagnosis and

and

and Testing

Testing

Manual transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17

Inspection and confirmation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fault Symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Removal/Installation

Manual Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Specifications

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Tightening Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Care and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 44

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MT Manual

Manual

Manual Transmission

Transmission

-16-

Instruction

Instruction and

and

and 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

gear)

synchronizer

. Shifting mechanism is of cable-type remote control.

Principles of motion:
1

gear

Engine→Clutch→Input shaft 1→Main gear of countershaft 15→Countershaft 11→

driving gear

6→1st/2nd gear

synchronizer 5→Output shaft 10
2

gear

Engine→Clutch→Input shaft 1→Main gear of countershaft 15→Countershaft 11→2

driving gear

4→1st/2nd gear

synchronizer 5→Output shaft 10
3

gear

Engine→Clutch→Input shaft 1→Main gear of countershaft 15→Countershaft 11→3

gear of countershaft 14→3

driving gear

3→3rd/4th gear synchronizer2→Output shaft 10

gear

Engine→Clutch→Input shaft 1→3rd/4th gear synchronizer 2→Output shaft 10
5

gear

Engine→Clutch→Input shaft 1→Main gear of countershaft 15→Countershaft 11→5

gear of countershaft 12→5

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 Manual

Manual

Manual Transmission

Transmission

-17-

Instruction

Instruction and

and

and Operation

Operation

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.

Please adopt low speed gear during vehicle
climbing, running downhill or turning. Don’t let
the vehicle idling with clutch released.

In case it is difficult to control the control handle,
please stop and inspect. Don’t apply it violently.

Kilometers

Kilometers applicable

applicable

applicable to

to each

each

each forward

forward

forward gear

gear

gear of

transmission:

Gear

Position

gear

Kilometers

0～15

20～30

35～45

50～60

65～75

Attention:

Gear

shifting

transmission

should

performed

performed within

within

within relevant

relevant

relevant kilometer

kilometer

kilometer range.

range.

The

The applicable

applicable

applicable kilometers

kilometers

kilometers may

may

may vary

vary

vary when

when

when the

the

transmission

transmission is

is equipped

equipped

equipped to

to different

different

different vehicles.

vehicles.

Principle

Principle of

of gear

gear

gear shifting

shifting

Under the forward running status, the requirements of
gear shifting is as follows: gear shifting from 1

gear to

gear step by step for speeding up, gear shifting from

gear to 1

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: In

In case

case

case of

of any

any

any emergency

emergency

emergency occurs

occurs

occurs during

during

running

running state,

state,

state, you

you

you may

may

may perform

perform

perform gear

gear

gear shifting

shifting

without

without following

following

following this

this

this principle

principle

principle.

Meaning

Meaning of

of transmission

transmission

transmission name:

name:

Inspection

Inspection and

and

and Confirmation

Confirmation

Check input shaft assembly

Check input shaft for gear teeth fracture, pitting,
severe wear or scuffing of tooth surface. If any,
please replace the input shaft.

Check input shaft spline for any severe wear or
damage. If any, please replace the input shaft.

Rotate bearing by hand to check for non-flexible
rotation or sticking. If any, please replace the

bearing.
Note:

Note:

Please check the stop ring on bearing during
replacement of bearing. If it is deformed, please
replace it.

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:

Rotate bearing by hand to check for non-flexible
rotation or sticking. If any, please replace the
bearing.

Check synchronizer ring

Check tooth surface of synchronizer ring for any
damage.

Check conical surface for any damage or wear;
check if the screw is crushed.

When the synchronizer ring is pressed close to gear,
check clearance “A”. If “A” is below the limit,
please replace the ring.

Limit

Limit value:

value:

value: 0.5mm

0.5mm

Check synchronizer gear sleeve and gear hub

Assemble the synchronizer gear sleeve and gear
hub together and check for smooth sliding but no
sticking.

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 Manual

Manual

Manual Transmission

Transmission

-18-

Instruction

Instruction and

and

and Operation

Operation

Fault

Fault diagnosis

diagnosis

Common

Common fault

fault

fault diagnosis

diagnosis

diagnosis table

table

Fault Symptom

Possible Cause

Solution

Jumping

back

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

shifting

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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JAC HFC4DA1-2C engine. Service Manual — part 31

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