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Engine JAC HFC4DA1-2C. Manual - part 120

Chassis

Chassis Volume

Volume

Volume Contents

Contents

- 3 -

Steering

Steering 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 and

and

and 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 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 List

List

List—

—

—SUNRAY

SUNRAY

SUNRAY Special

Special

Special Service

Service

Service Tools

Tools

CL Clutch

Clutch

- 1-

Clutch

Applied models: SUNRAY products manufactured by JAC

Subject

Page

Instruction

Instruction and

and

and Operation

Operation

Clutch...............................................................................................................................................................................1

Explosive View of Clutch........................................................................................................................................... 1
Introduction of Clutch................................................................................................................................................ 1

Diagnosis

Diagnosis and

and

and Testing

Testing

Clutch...............................................................................................................................................................................2

Operating Principle.....................................................................................................................................................2
Inspection and Maintenance....................................................................................................................................... 3
Fault Symptom Table..................................................................................................................................................4

Removal

Removal and

and

and Installation

Installation

Clutch...............................................................................................................................................................................7

Specification

Specification.................................................................................................................................................................. 14

Tightening Torque.....................................................................................................................................................14

CL Clutch

Clutch

- 2-

Instruction

Instruction and

and

and Operation

Operation

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 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,

Content .. 118 119 120 121 ..