Content .. 129 130 131 132 ..

Engine JAC HFC4DA1-2C. Manual - part 131

MT Manual

Manual

Manual Transmission

Transmission

-44-

Care

Care and

and

and maintenance

maintenance

Transmission

Transmission maintenance

maintenance

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.

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

－

Odometer reading×1000km

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.

Running on bumpy, water-logging roads or on mountain road.

Running in cold areas.

Engine idling for a long time or frequent short distance running in cold seasons.

Frequent application of brakes and emergency brake.

Towing vehicle.

Under high temperature over 32℃, the time of vehicle running slowly in congested urban areas exceeding 50%
of total running time.

Under high temperature over 30℃, the time of vehicle running at high speed over 120km/h exceeding 50% of
total running time.

Overloading.

Lubrication and seal

Item

Lube

Lube Oil/Sealant

Oil/Sealant

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 Brake

Brake

Brake System

System

- 45-

Brake

Brake System

System

Applied models: SUNRAY products manufactured by JAC

Subject

Page

Instruction

Instruction and

and

and Operation

Operation

Brake System................................................................................................................................................................. 46

Explosive View......................................................................................................................................................... 46
Introduction of Brake................................................................................................................................................47

Diagnosis

Diagnosis and

and

and Testing

Testing

Brake System................................................................................................................................................................. 49

Inspection and confirmation..................................................................................................................................... 52
Fault Symptom Table................................................................................................................................................53

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 Brake

Brake

Brake System

System

- 46 -

Instruction

Instruction and

and

and 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 Brake

Brake

Brake System

System

- 47-

Instruction

Instruction and

and

and Operation

Operation

Operating

Operating principle

principle

Brake

Brake fluid

fluid

Inspection

Inspection of

of brake

brake

brake fluid

fluid

fluid level:

level:

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.

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 master

master

master cylinder

cylinder

On-vehicle

On-vehicle 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 of

of vacuum

vacuum

vacuum booster

booster

Operation inspection
Shut down the engine and repeatedly depress the
brake pedal for several times to make the vacuum
inside

the

vacuum

booster

equivalent

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.

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 disc

disc

disc brake

brake

brake caliper

caliper

On-vehicle

On-vehicle inspection:

inspection:

Check brake shoes for any wear.
Attention:

Attention:

Standard thickness: 12mm
Wear limit thickness: 2mm

Inspection

Inspection of

of brake

brake

brake disc:

disc:

Visual inspection
Check brake disc surface for uneven abrasion,
crack or sever damage. If any, please replace the
brake disc.

Inspection of runout
①

Fix the brake disc onto the wheel hub.

Attention:

Before measurement, please ensure proper axial
clearance of wheel bearing.

MAX

MIN

Good

Poor

Content .. 129 130 131 132 ..